Scaling up products from the laboratory to field trials to full production can often be problematic, whether a new polymer is being developed or a formulated finished adhesive is manufactured. If bond failures are occurring during production, the plant may go back to the adhesive supplier and claim the adhesive is at fault. However, it could be the case that the performance variability may be due to the manufacturing process rather than the quality of the adhesive. When the adhesive and the new application are in the development stage, special care is taken by the adhesive manufacturer to supply a consistent product, and the field trials are conducted under well-controlled conditions.
Let’s explore the potential pitfalls in the use of a two-component waterborne polyurethane that is crosslinked with a polyisocyanate. Adhesives of this type are used in furniture and automotive applications. The adhesive needs to develop high bond strength in a short period of time, which often means minutes rather than of hours.