Content area
Full text
Coachman Caravans, a Northern England-based manufacturer of touring caravans, has upgraded its production facility in response to increased demand in Continental Europe. The company has been able to increase production of caravan shells, reduce emissions of volatile organic compounds and improve quality by using the Solfre 2 two part polyurethane system developed by Chemique Adhesives and Sealants, Aldridge, United Kingdom.
The shells of the caravans are constructed from laminated panels using aluminum, foam and plywood substrates. Once purchased, the caravans are usually left outside in weather conditions ranging from winter temperatures below freezing to summer temperatures up to 100degF in Southern Europe. Such exposure conditions require a continuous bond between substrates: if there are gaps, the expansion/contraction of the trapped air pocket can build up pressure over time and cause a delamination in the caravan panel. With a 20-year expected service life, the adhesive used to bond panel substrates must offer a durable, long-lasting bond line able to withstand pressures likely to be encountered during extended use.
Coachman was already using a solvented urethane to manufacture the panels, but was being forced to consider a change because of tight U.K. environmental legislation and the pressure of higher demand for Coachman products. According to George Kemp, joint managing director of Coachman, "We had to find a way to increase production quickly, or we could not have kept pace with increased demand. At the same time, I was not willing to make any sacrifices in the quality of our caravans to achieve greater volume."
To solve the environmental problem, the company considered Solfre 2 alongside competing solvent free systems, usually based on moisture curing polyurethane with 100% solids content. During an extensive selection procedure, a variety of adhesive manufacturers were invited to demonstrate their systems in operation by manufacturing Coachman panels. The company considered ease of use, panel quality, potential savings and supplier reliability before eventually opting for the Solfre 2 system, a two component polyurethane adhesive designed specifically for panel lamination. "We were convinced that Solfre 2 could offer us the production gains that we required and could actually improve panel quality," says Colin Newton, production manager at Coachman. "Other systems were too complex and would have required the measurement of relative humidity in the...