Lamination is the process of bonding two or more sheets or layers of materials together to create a stronger product. Foam lamination in particular is a surface modification method used to enhance the structural performance and properties of a given material. The process is often used to form a composite material, a combination of layers of numerous different materials. It is used in a wide variety of industries, with different types of laminated foam materials offering different specific benefits. Stick with us to learn about the diverse types, applications and general benefits of laminated foam.
Types of Foam Lamination:
PUR (polyurethane reactive) adhesive lamination
This type of lamination process is carried out using a reactive hot-melt adhesive. Heated before processing, the adhesive is applied in a molten state, creating an instantaneous bond between materials as it cools. Once it has come into contact with moisture, it will form a stronger bond that’s finalised at the end of the curing process. Solvent-free, PUR is an environmentally friendly and non-toxic adhesive that’s easy to transport as it doesn’t react with fire. It’s also extremely efficient. PUR adhesive lamination has a wide variety of applications, including car assembly, medical products, military supplies and more.
We are proud to be the UK’s premier PUR adhesive lamination specialists, providing total end-to-end solutions through our complete in-house manufacturing service.
A type of continuous lamination, this foam lamination process involves laminating flexible materials with the heat from an open flame, creating a layer of thin molten polymer on the surface. It’s a popular lamination choice because it doesn’t require adhesive, meaning the costs are lower. Plus, it’s easier to recycle, too! Flame lamination is particularly effective in bonding soft, flexible foams to fabrics as well as paper and films, but has a wide array of applications across a range of industries.
In practice, this process is similar to flame lamination, producing a thin layer of molten polymer on the surface of your chosen material. Infrared laminating ovens are used throughout the automotive, textile and glass industries to create materials that provide increased protection and durability.
Using adhesive dots placed on the surface of one material to bond it to another, this type of foam lamination is commonly used to add valuable properties to a product. Unlike flame lamination, the material itself is not relied on to act as adhesive. Layers are warmed with the adhesive and then cooled off. However, this takes place on a calander or flatbed press, in order to ensure even distribution. This is different from other types of laminations in that it facilitates the bonding of a wider range of materials, including, fleece, films and leather.
The main benefits of foam lamination
Improve the structural properties of a material
Foam lamination is a technique used to enhance the properties of your material of choice. If you’re looking to improve the fire or water resistance of a material, choose foam lamination.
Generally speaking, foam is cheaper than other materials you may find on the market. It’s an efficient form of lamination that won’t break the bank. Foam lamination enables you to create a durable product at a competitive price point, thus adding value, regardless of the industry you work in.
It’s important to be able to choose from different types of foam lamination according to your needs. What properties are you adding to your product? This is perhaps the most critical question to consider when making your final decision. Whether you’re looking to add protection, durability or fire protection or aiming to make a product more lightweight, there are several choices that our expert team can guide you through.
Discover which type of laminated foam is best for you by reading our guide here.