At a time where there is ever-increasing scrutiny around the use of hazardous materials, and greater demand on speed and efficiency in production industries, many manufacturers are turning to hot melt adhesives as the answer.
In the vehicle construction and professional modification industries specifically, manufacturers are looking for new technologies which can handle demanding applications in vehicle construction, without compromising on strength and build-time.
Hot melt adhesives are a strong option because they are fast to apply, set quickly, and avoid the curing delays and solvent issues associated with many liquid adhesives.
Why hot melts work so well in this environment
Compared to water and solvent-based adhesive systems, hot melt adhesives dramatically cut back on waiting times and safety concerns, ultimately contributing to smoother processes and increased production speeds.
As hot melts cool and solidify to form bonds, as opposed to water or solvent evaporation, they can form a solid join within minutes of compression. In many cases, bonds formed with water or solvent-based adhesives are not fully secure until 24 or even 48 hours after compression. The faster bonding speed of hot melts allows completed parts to be moved through the production line almost immediately, without the worry of bond failure.
Hot melts are also non-toxic and VOC-free, negating the need for any respiratory PPE or air extraction equipment in manufacturing facilities. As legislation on the use of hazardous materials in workplaces becomes more stringent, adopting a VOC-free technology such as hot melts can prevent businesses from incurring any fines or legal action in the future.
Some of the other benefits include the diversity of materials hot melts can bond, and their ability to be used as a gap-filler in certain circumstances.
Common uses for hot melts in the automotive industry
Due to their reliability and varied substrate compatibility, hot melts are commonly used for:
- Interior trim attachments (door panels, edging, dashboard componentry, finishing trims etc)
- Cable & Conduit tracking (wire management and bundle routing where applicable)
- Insulation or acoustic materials
- Light-duty fixture bonding (non-structural brackets, spacers, protective elements)
- Temporary positioning (instant hold capabilities before a mechanical fastening)
- Panel and lining assembly (in fit-out systems)
It’s worth noting that hot melts are ideal for any bonds that are classed as “non-structural”. Structural bonds can be temporarily secured using hot melts, but should always be properly secured with a high-strength structural adhesive or mechanical fastener.
Tecbond Hot Melts – The next step in hot melt bonding for commercial vehicles
What sets Tecbond hot melts apart from other hot melts, are their versatility and options beyond of traditional stick or bulk formats. Many Tecbond formulations are available in 43mm slug format for demanding applications where high-output is essential. Alongside this, some 43mm adhesives can be used in conjunction with the Tec spray applicators, creating a more user-friendly and cost-effective alternative to aerosol adhesives. Detailed below are some of the substrates and applications Tecbond hot melts are commonly used for.
Plastic Bonding
A common finishing material in the automotive industry, versatile plastics (such as polypropylene and polyethylene), have proven very challenging to bond due to their low surface tension, which makes it difficult for any chemical bonding to take place (for more information on physical and chemical bonding, check out our blog on the two types of bonding).
Tecbond 268 is a specialist plastic bonding adhesive, specifically designed to bond these difficult plastics, alongside other “shiny” substrates with low surface tension. For this reason, Tecbond 268 has become the staple choice for many manufacturers in the refrigerated vehicle industry, as it excels at bonding the polypropylene covering over the insulation panels used to keep the vehicle cool. The formulation has also been used to fix dashboard pieces, and decorative wall panelling in custom fit-outs.
Fabric coverings & linings
Another popular use for Tecbond hot melts is the bonding of fabrics to a wide range of substrates, including heat-sensitive materials such as foam.
The unique application method for Tecbond sprayable hot melts mean they can be applied to heat-sensitive materials without causing damage, but still provide a strong, near instant tack and reliable final bond. With many manufacturers being forced to move away from solvent-based adhesives, and the potential mould risk posed by water-based adhesives, Tecbond sprayable hot melts have already been adopted in the bonding of:
- Roof liners
- Seat manufacture (cushion bonding and fabric to cushion bonding)
- Floor coverings
Insulation Panelling
Many UK-based refrigerated vehicle manufacturers have already switched over to Tecbond sprayable adhesives for their insulation bonding. Many other adhesives either an open time that is too short, meaning the adhesive cures or sets before the bond is made, or the bonding time is too long, requiring constant compression over a period of hours.
Tecbond sprayable hot melts, on the other hand, have the open time required for large panel bonding, with the high initial tack to hold the panel in place without extended compression periods.
Hot melt adhesives can dramatically improve speed and consistency in commercial vehicle construction and modification. Tecbond plastic bonding adhesives help tackle the reality of plastic-heavy interiors and trims, while Tecbond sprayable hot melts are ideal when coverage and substrate integrity are the priorities on large-area bonding tasks.
If you want a more robust, production-friendly bonding process, the best next step is to map your most common substrates and assemblies—then match the Tecbond grade and application method (bead vs spray) to each one.
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