The Lamination industry involves the bonding of a multitude of complex materials, insulation and structures. Adhesive laminating technology is found in a range of applications including in insulated panels, in composite materials, in door manufacturing, and textiles and laminate bonding. Maxilam specializes in polyurethane chemistry for an array of high-performance lamination applications, improving adhesion, eliminating delamination, and improving production efficiency.
A manufacturer of composite panels was experiencing inconsistency of adhesion with their panel lamination. Extensive manual operational processes were being carried out due to the limited understanding of polyurethane adhesion and curing processes. This then was leading to output inconsistency and delamination occurring.
Poor control of the production variables such as the water-mist ratio, open time and total cycle time was the root cause of the adhesion inconsistency. Focus was misplaced upon the moisture content rather than during the adhesive application. The low water-mist to adhesive ratio was impacting the adhesives ability to cure consistently in the press and therefore causing the delamination.
Maxilam’s suggestion was to transition to a bespoke Sabre® PU single component moisture curing laminating adhesive. This provided higher adhesion properties and greater flexibility across diverse materials and operational environments. Our client was assisted in the reconfiguring process where we increased the water-mist ratio as a ratio of the adhesive coat weight, but also paid attention to the management of four critical production variables: Water-mist ratio, room temperature, open times and total cycle time.
As a result of this process through stronger, more resilient and flexible adhesive properties, the client was able to eliminate delamination, remove wastage and reduce warranty claims. As a result, the client was able to double the production rate because of the better control of production variables and more flexible operational parameters.
Sandwich Panel Manufacturing covers various industries such as RV, Transport, and Defense composite structures. This then comprising a diverse array of exterior layers laminated to intermediate layers or cores. Single-component adhesive innovation by Maxilam delivers fast transforming sandwich panel lamination for manufacturers, whilst also revolutionizing the production environment.
Structural Insulated Panels (SIP) constructions involve the lamination process consisting of EPS, XPS, or mineral wool, sandwiched between exterior boards. SIP systems are used predominantly in prefabricated residential and commercial construction. They are fast revolutionizing traditional construction methods. They are doing so by offering cost, energy and time savings, whilst also providing solutions that are versatile and durable.
Bonding wood materials involve the lamination processes of many different non-structural and structural wooden components, across the lamination of structural beams, glu-lam, laminates, finger-joints and many more. With the applications for wood being so great because of their natural properties, manufacturers place increased demand on solutions that are flexible, durable, and sustainable.
Door manufacturing processes involve the bonding and lamination of various layers and substrates, through various methods. Listening to the key challenges, constraints, and issues of leading manufacturers has enabled us to develop solutions for complex environments.
Sabre Grip represents our specialist range of highly developed, and advanced pressurized, solvented canister adhesive systems. These are developed for diverse applications where flexibility and application speeds are critical. The Sabre Grip spray canister system provides a faster and cleaner application, saving users time which in turn increases bottom line profitability.
Innovation is in our DNA. Maxilam offers bespoke adhesive formulations in order to solve unique client challenges and provide fit for purpose solutions. With a strong technical presence, many leading organisations have partnered with Maxilam to create unique innovations and achieve precise results together. Our portfolio for innovation extends across multiple sectors and product chemistries.