Best adhesive for polypropylene (PP) honeycomb panels

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Glue for polypropylene (PP) honeycomb panels

Polypropylene (PP) honeycomb panels are ideal for use in the automotive industry. These innovative panels, combined with the right glue, are the perfect basis for the construction of various vehicles. But what makes them so unique? And why does the right adhesive play a critical role in the success of these panels? Find out everything you need to know about PP panels and their potential for durable and efficient construction and make the switch. We are here to help.

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What are Polypropylene (PP) Honeycomb Panels?

Polypropylene (PP) Honeycomb Panels are panels that consist of a honeycomb polypropylene core and glass fiber reinforced outer layers.

This construction of the panels ensures that the panels are lightweight but ironclad. The honeycomb shapes in the panels provide a strong core. In addition, the honeycombs in the panels have an insulating effect. This also provides benefits.

The fiberglass finish provides additional reinforcement on the outside. This makes the material extra stiff and strong. As a result, the panels have an excellent ability to support heavy loads without sagging.

The panels are available in various thicknesses. Naturally, the thicker the panel, the stronger it is. But even with a small thickness, it can withstand considerable impact.

PP honeycomb panels vs massive polypropylene

Compared to solid polypropylene, PP honeycomb panels are lighter and stronger. This makes them a much more efficient choice for applications where weight is a factor, such as in the automotive industry.

Compared to materials such as polycarbonate, PP honeycomb panels are also stronger. The panels withstand impacts well and are more stable in high winds or hail, for example. In short, PP honeycomb panels are a good choice because of the various advantages offered by the honeycomb structure.

How can PP honeycomb panels be processed?

Polypropylene panels can be easily formed into a variety of shapes, making them ideal for complex structures. They are flexible enough to bend after a few notches and can be finished with a variety of materials such as paint, anti-slip or specialty coatings.

Bonding with metals like aluminum and other materials

PP panels can be bonded to metal parts, for example for structures in the automotive industry. You can use mechanical fasteners and drill and screw into the panels.

But you get the most out of the material by choosing bonding. Gluing polypropylene panels has many advantages, including:

Glue keeps the structure lightweight.
Glue makes the panels easier to recycle.
Glue leaves the panels intact. No holes need to be made in the structure, so the panels last longer. The insulating properties are also retained.

Polypropylene honeycomb panels in automotive

The polypropylene sheets, in combination with bonding, provide the ideal basis for automotive applications. The advantages of the material and the flexibility of the panels in terms of processing make them versatile. They are particularly suitable for use in vehicles for roofs, walls and even floors.

Benefits of honeycomb panels in the automotive industry

Lightweight and fuel economy

One of the biggest advantages of polypropylene (PP) honeycomb panels is their lightweight construction. This not only makes vehicles more efficient, but also reduces fuel consumption and CO2 emissions. Lighter vehicles are more maneuverable, faster and have a higher load capacity, making them ideal for applications such as caravans, refrigerated trucks, vans and commercial vehicles.

Insulation

The honeycomb structure of the PP panels provides a natural insulating effect, ensuring temperature maintenance in refrigerated vehicles.

Strong, Less Damage and Maintenance Costs

Strong, Less Damage and Maintenance Costs The lightweight panels not only contribute to greater ride comfort, they are also very strong. They resist corrosion and can withstand heavy impacts and extreme weather conditions.

This saves on maintenance costs and limits damage. Useful when the vehicle carries heavy materials or is used intensively.

And if a dent does occur in the panel, it can be easily repaired without having to replace the panel.

Different types of polypropylene honeycomb panels in automotive

There are several types of panels that are widely used in the automotive industry. One of the best known is MonoPan®. These panels are ideal for the basic structure of the front of the vehicle and for application in walls and roofs.

Twintex is another type of polypropylene widely used in the automotive industry. It does not have a pronounced honeycomb structure, but is a blend of polypropylene and glass fiber. Because Twintex can be thermally processed well, it is widely used in interior applications such as dashboards.

A third option is Holypan. This contains the same honeycomb structure as Monopan, with fiberglass layers on the outside, but the honeycomb structure is closed instead of open. This gives Holypan an even better insulating effect, but the product is slightly heavier than Monopan. A good choice for vehicles where insulation is important.

Applications of PP honeycomb panels and bonding in automotive

Polypropylene (PP) honeycomb panels are used in a wide range of vehicles within the automotive industry. Their lightweight, strength and insulating properties make them ideal for use in the following vehicles:

Passenger and commercial vehicles

Caravans and motor homes (walls, floors and roofs).
Motorhomes and RVs.
Cargo vans and delivery vans.

Trailers

Semi-trailers en flatbed trailers.
Koeltrailers (reefer trailers) en geïsoleerde trailers.
Curtainsider trailers en tautliners.
Utility trailers en multi-purpose trailers.
Boat trailers, bike trailers en camping trailers.
Livestock trailers en horse trailers.
Car trailers en heavy equipment trailers.

Specialty Vehicles

Ambulances and Fire Trucks (Light and Rigid).
Food trucks and box trucks.
Refrigerated trucks for temperature-sensitive shipments.
Mobile workshops and container chassis.

Compact structures

Bicycle trailers.
Containers for different applications.

Polypropylene adhesive glue: how does it work?

Because polypropylene itself has a low surface tension, it requires processing and a special adhesive to bond properly. Standard adhesives do not provide sufficient adhesion for bonding in the automotive industry.

To bond panels together or to bond materials such as aluminum to the panels, polypropylene adhesive is required. Three steps are required in the application of the adhesive for a permanent bond:

Clean the surface to remove dirt, grease and dust that can reduce adhesion.
Use a primer. This is necessary to fill any unevenness in the panels and create a larger contact area.
Use a special polypropylene adhesive that works perfectly on PP honeycomb panels.

The advantages of polypropylene glue

We briefly mentioned above that bonding has an advantage over using screws and bolts because of its weight and durability. Bonding also allows the structure to retain better insulation.

But bonding has many other advantages over traditional metal fasteners.

High Impact Strength and Flexibility: The adhesive provides a strong but elastic bond that can withstand vibration and shock, which is critical for automotive applications.

Waterproof and weather resistant: The adhesive can withstand extreme weather conditions such as rain, heat and cold, extending the life of the joint.

Seamless finish: Unlike screws or bolts, the adhesive provides a tight finish with no gaps or visible joints.

Longer life: Bonding prevents material damage such as cracking or warping, making the structure last longer.

Fast application time: Although the three steps are required for proper bonding, adhesive bonding is faster than screwing or other mechanical fasteners.

Sustainability and the Use of Polypropylene Glue

As adhesives+coatings, we are committed to using sustainable adhesives and coatings. We strongly support the use of polypropylene honeycomb adhesive. Not so much because the adhesive is biodegradable, but because it offers benefits in a number of environmental areas:

Reduced CO2 emissions from vehicles due to lighter construction.
The strength of the construction, giving it a very long life and requiring less maintenance.
No metal required for joints.
Greater ability to recycle the panels.

So we looked for the right adhesive to handle the panels and ensure their long life.

Test results of the best adhesive for polypropylene

The PP adhesive we can recommend has excellent test results. The adhesive for polypropylene honeycomb panels has undergone rigorous testing to validate its strength, durability and suitability for demanding applications such as automotive. Below are some highlights from the test results:

1. Load and Stress Testing

Adhesive bonding between polypropylene honeycomb panels and aluminum profiles was tested under load conditions. The results demonstrated:

Cohesive failure: The bond was so strong that when stress was applied, failure occurred in the polypropylene panel itself rather than in the adhesive joint. This indicates that the adhesive bond exceeded the strength of the material it was joining.
High shear and tensile strength: The bond withstood significant mechanical stress without breaking or losing integrity.

2. Weather Resistance

Tests confirmed that the adhesive maintains its performance under extreme environmental conditions, including:

Temperature fluctuations: Reliable bonding in both high and low temperatures.
Moisture and UV exposure: No degradation in bond quality when exposed to humidity or prolonged sunlight.

3. Case Study: Panel and Profile Bonding

In a test where aluminum rails were bonded to polypropylene honeycomb panels::

The adhesive showed excellent bonding strength.
Even when the aluminum profile was subjected to force, the adhesive bond remained intact, demonstrating superior durability.

Making the switch to PP honeycomb panels?

Are you curious about the detailed test results and the possibilities of using PP honeycomb panels in combination with bonding for your production process? Then please contact us. We will be happy to help you achieve efficient and sustainable production.

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