A New Path for Lamination Adhesives: Leaping Barriers and Erasing Steps The benefits of a novel one-component waterborne adhesive for automotive interior lamination May 9, 207 John White
Interior Lamination SKIN PVC TPO LEATHER FOIL FOAM PE PP PU RIGID POLYMER PP ABS PC-ABS DOOR PANEL INSTRUMENT PANEL CONSOLE 2
Laminating Adhesives TYPE PROS CONS K Waterborne ( PL 50P) 0 VOC Cure 70 C Must remove water 2K Waterborne ( PL 3300) K Solvent-borne, 2K Solvent-borne Reactive Hot-melt (TECHNOMELT PUR 9622-02) 0 VOC Cure 60 C Quick dry Sometimes no pretreatment 00% solids One-sided application Must remove water VOC emissions Solvent exposure Hot safety hazard Very difficult to clean 3
VOI, g/l Components Example VOC, g/l Quick Dry Low Cure Temp Pot Life Open On-Part Life Cleanup Safety Exposure WATER 2 PL 50 P PL 3300 + + - + + + + + + + - - + + - + + - - - - - - - HOT MELT TECHNOME LT PUR 622 + + + + - - + + - - - - - - - - - + - + -? + + - - SOLVENT 2 - - + + + - - - - - - + if immediate - - 4
Quick Dry Components Example VOC, g/l Quick Dry Low Cure Temp Pot Life Open On-Part Life Cleanup Safety Exposure WATER 2 PL 50 P PL 3300 + + - + + + + + + + - - + + - + + - - - - - - - HOT MELT TECHNOME LT PUR 622 + + + + - - + + - - - - - - - - - + - + -? + + - - SOLVENT 2 - - + + + - - - - - - + if immediate - - 5
Low Cure Temp Components Example VOC, g/l Quick Dry Low Cure Temp Pot Life Open On-Part Life Cleanup Safety Exposure WATER 2 PL 50 P PL 3300 + + - + + + + + + + - - + + - + + - - - - - - - HOT MELT TECHNOME LT PUR 622 + + + + - - + + - - - - - - - - - + - + -? + + - - SOLVENT 2 - - + + + - - - - - - + if immediate - - 6
Pot Life Components Example VOC, g/l Quick Dry Low Cure Temp Pot Life Open On-Part Life Cleanup Safety Exposure WATER 2 PL 50 P PL 3300 + + - + + + + + + + - - + + - + + - - - - - - - HOT MELT TECHNOME LT PUR 622 + + + + - - + + - - - - - - - - - + - + -? + + - - SOLVENT 2 - - + + + - - - - - - + if immediate - - 7
Open Components Example VOC, g/l Quick Dry Low Cure Temp Pot Life Open On-Part Life Cleanup Safety Exposure WATER 2 PL 50 P PL 3300 + + - + + + + + + + - - + + - + + - - - - - - - HOT MELT TECHNOME LT PUR 622 + + + + - - + + - - - - - - - - - + - + -? + + - - SOLVENT 2 - - + + + - - - - - - + if immediate - - 8
On-Part Life Components Example VOC, g/l Quick Dry Low Cure Temp Pot Life Open On-Part Life Cleanup Safety Exposure WATER 2 PL 50 P PL 3300 + + - + + + + + + + - - + + - + + - - - - - - - HOT MELT TECHNOME LT PUR 622 + + + + - - + + - - - - - - - - - + - + -? + + - - SOLVENT 2 - - + + + - - - - - - + if immediate - - 9
Cleanup Components Example VOC, g/l Quick Dry Low Cure Temp Pot Life Open On-Part Life Cleanup Safety Exposure WATER 2 PL 50 P PL 3300 + + - + + + + + + + - - + + - + + - - - - - - - HOT MELT TECHNOME LT PUR 622 + + + + - - + + - - - - - - - - - + - + -? + + - - SOLVENT 2 - - + + + - - - - - - + if immediate - - 0
Safety Exposure Components Example VOC, g/l Quick Dry Low Cure Temp Pot Life Open On-Part Life Cleanup Safety Exposure WATER 2 PL 50 P PL 3300 + + - + + + + + + + - - + + - + + - - - - - - - HOT MELT TECHNOME LT PUR 622 + + + + - - + + - - - - - - - - - + - + -? + + - - SOLVENT 2 - - + + + - - - - - - + if immediate - -
Two-Component Versus One-Component Processing Two-Component Processing One-Component Processing 2
Drying of PL 50 P Film 60 Maximum film temperature while drying Temperature [ C] 50 40 30 20 Entry of film into dryoff oven Dried film at the end of the dryoff oven Laminate immediately Laminate later 0 0-0 2 3 4 5 6 7, Minutes 3
K Waterbased Low Temp Cure Adhesive PL 50 P Strength Activate Green Strength: Cohesive Failure Substrate Failure Foam Tear Bladder Removal Edge fold release CURED CURING COOLING One minute One hour One day 4
Good Adhesion Requires: Surface Energy > 45 d/cm Substrate composition Pretreatment Surface contamination Heat Dry RT 50 C acceptable range 0 8% remaining water acceptable range (non-porous substrate) Activate 70 40 C+ acceptable range OK to dry and activate in one cycle Coat weight Non porous substrate: 00 GSM wet - foil 00 GSM per side wet - rigid part 5
Robust Activation 3000 2500 PL 50 P Performance at 70 C for Vinyl Skin to Spacer LOAD (N/m) 2000 500 000 500 0 0 20 40 60 80 00 REACTIVATION TIME (sec) 6
Robust Activation and Temperature 3500 3000 Performance Capabilities of PL 50 P at Varying Temperatures for Spacer to TPO 80C 75C LOAD (N/m) 2500 2000 500 000 85C 70C 500 0 0 0 20 30 40 50 60 70 80 90 00 REACTIVATION TIME (sec) 7
Application to Difficult Substrates Part type: Porous vs Non-porous PL 50 P total GSM for Skin to Spacer PL 50 P Total GSM for Spacer to TPO 3500 3500 3000 3000 2500 2500 2000 2000 (N/m) 500 (N/m) 500 000 000 500 500 0 0 200 250 300 350 400 450 002 50 200 250 Total GSM GSM This case shows how 50 P was successfully applied to difficult substrates, passing strict requirements 8
Three Process Scenarios /3 Activate with coated surfaces separate. CONTROL Separate, 20 C for 2 minutes (87 C Bondline) SAMPLE LOAD (N) LOAD (N/M) FAILURE MODE 37.48 475.59 Cohesive 2 Heat after laminating 90 C bondline. 2 34.76 368.69 Cohesive 3 72.83 2867.49 Cohesive 4 60.09 2365.67 Cohesive 3 Test before Climate Test. 5 78.92 307.27 Cohesive Average 56.82 2236.94 Cohesive 9
Three Process Scenarios 2/3 Activate with coated surfaces separate. CLIMATE TEST Separate, 20 C for 2 minutes (95-00 C Bondline) SAMPLE LOAD (N) LOAD (N/M) FAILURE MODE 82.86 3262.08 Cohesive 2 Heat after laminating 00 C bondline. 2 98.57 3880.6 Cohesive 3 07.27 4223.38 Cohesive 4 80.7 377.25 Cohesive 3 Test after Climate Test. 5 92.28 3632.88 Cohesive Average 92.34 3635.24 Cohesive 20
Three Process Scenarios 3/3 CLIMATE TEST Together, 20 C for 4 minutes Activate with coated surfaces mated. 2 Heat after mating 4 min 20 C. SAMPLE LOAD (N) LOAD (N/M) FAILURE MODE 8.35 3202.9 Cohesive 2 88.98 3503.34 Cohesive 3 92.29 3633.35 Cohesive 4 9.6 3606.73 Cohesive 3 Test after Climate Test. 5 59.89 2357.75 Cohesive Average 82.82 3260.82 Cohesive 2
Meeting Global Specifications In testing to date, PL 50 P meets the specifications of major, global OEMs. 22
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