What is Foam Lamination
Foam lamination is a necessary step in the production of foam composites because it allows two types of materials to be merged into one element.
It is a very effective procedure for bonding foam not only to foam, but also to other materials such as glue, cloth, film, foil, and other things. It is a necessary step in the production of foam composites and complex foam products. PSA lamination and flame lamination are the two most common lamination processes (heat lamination)
However, there are different types of materials used in lamination. The choice of foam materials for lamination depends on the specific applications and the properties required. For example, if high shock absorption is required, then foam with great cushioning properties like PE foam may be more suitable. If resistance to water and chemicals is required, then a foam such as PU (Polyurethane) foam or XLPE (Cross-linked polyethylene) foam may be more suitable.
What are the Benefits of Foam Lamination
Foam lamination offers several benefits over other bonding methods, like gluing, welding, and stitching. Some of the main benefits foam lamination offers include:
Improved comfort: Foam lamination can provide a comfortable and soft surface for users. This makes it an ideal choice for products that come into contact with the skin, like footwear, clothing, and sports equipment.
Enhanced durability: Foam lamination can enhance the toughness and strength of a product by creating a bond that spreads stress and prevents tearing or ripping. This is particularly useful for products that are subjected to high stress or impact, such as backpacks or luggage.
Improved safety: Foam lamination can provide further safety features by establishing a barrier that stops penetration or puncture, such as in protective gear or medical devices.
Why choose our Foam Lamination
Over the last 20 years, our abilities and knowledge has expanded into additional industries, giving us the ability to design and laminate many different products including floor underlay, automotive textiles, sport and leisure equipment, apparel, luggage goods and so much more.
Get in touch to discuss your foam lamination needs with an expert member of our team.
Features of Foam Lamination
Foam lamination can be used with a variety of foam materials. This makes it a popular choice for many industries because the versatile bonding method suits many different applications. It can also be used to customise bespoke requirements, like thickness, density, and colours.
Foam lamination is also a strong material which can provide a strong bond between the foam and the substrate, distributing stress and reducing tearing or delamination.
For added comfort, foam lamination is perfect. This is because it provides a soft and comfortable surface for users, which makes it an ideal choice for products that come into contact with the skin, such as clothing, footwear, and sports equipment.
Foam lamination can provide thermal and acoustic insulation, which makes it an ideal choice for products that require temperature control or noise reduction, such as camping gear or automotive components.
Foam lamination will improve the toughness and strength of a product by establishing a strong bond that distributes stress and prevents tearing or ripping. This is especially handy for products that are subjected to high stress or impact, such as backpacks or luggage.
They also provide a lightweight solution, which is important for products that require a low weight-to-strength ratio, like automotive interiors and aerospace components. Foam lamination can provide additional safety features by creating a barrier that prevents penetration or puncture, such as in protective gear or medical devices.
Applications of Foam Lamination
Automotive industry: Foam lamination is used heavily in the automotive industry, for interior designs. Foam lamination is used for noise reduction, thermal insulations, as well as improved aesthetics. They are also used in the production of car seats and headliners for added durability and comfort.
Medical industry: Foam lamination is used in medical devices, such as braces and prosthetics, for added comfort and support. It is also used in the production of splints, gaskets and sealing.
Footwear industry: Foam lamination is used in the assembly of footwear for added support, cushioning and comfort. They are also used to create waterproof and breathable barriers in shoes.
Aerospace industry: Foam lamination is used in the production of aircraft interiors for added comfort, noise, and weight reduction.
Sports industry: Foam lamination is used in the production of sports equipment, such as padding and protective gear, for improved shock absorption and protection. It is also used in the production of sports apparel for added comfort and support.
Construction industry: Foam lamination is used in the production of insulation materials for thermal and acoustic insulation. It is also used in the production of roofing materials for added durability and weather resistance.
Overall, foam lamination is a very versatile bonding method that can be used in many different industries to provide added comfort, durability, and protection.
The Foam Lamination Process
Foam lamination is used in a variety of industries, for an array of purposes. From packaging, construction, medical cushioning, and transportation. This versatile material helps to boast numerous advantages that make foam lamination a popular process.
Put simply, foam lamination consists of a foam material which is bonded to either additional foam or other materials. There are numerous ways of producing foam lamination, each of which is beneficial in certain ways.
The Three Types of Foam Lamination
Foam lamination is a process that involves bonding foam materials together to create a composite structure with enhanced properties. This technique is widely used in various industries, including automotive, aerospace, sports, and medical manufacturing, as mentioned above.
Hot Melt Adhesive Lamination
At Archbond, we use Pur Hot-Melt Adhesives. This is so we can produce both glossy and matte laminated foam materials. One of the major advantages of Pur Hot Melt Lamination, is that the end material can be created quickly, as it solidifies as soon as the industrial adhesive has cooled.
Whether you’re looking to create large surface products like mattresses or need a stronger foam material for use in HVAC systems. Hot melt lamination is the ideal solution for you.
Flame lamination is another type of thermal lamination process. Unlike hot-melt lamination, which requires the use of a separate adhesive, flame lamination can be carried out using the substrates to be bonded. One of the main advantages of flame lamination, is that is does not require any adhesive.
The process tends to work best when bonding flexible layers of foam to non-woven fabrics but it’s also ideal for bonding foam to paper-based products and films.
The infrared lamination process is similar to the flame lamination, as it doesn’t require any adhesive. Its therefore another cost-effective, sustainable solution for creating your ideal composite materials. The infrared lamination process is ideal for creating a stable bond between different substrates of materials.
It creates incredibly durable laminated-foam-based products, which are highly protective, making them ideal for use in a variety of industrial uses, including the automotive sector.
PU vs PE foam
The two most common types of laminated foam are PE (polyethylene) and PU (polyurethane) foam. Both materials prove incredibly useful when it comes to enhancing performance, but PU foam tends to be thicker and softer, providing greater cushioning properties.
Conversely, PE foam triumphs if you’re looking for a firm foam composite material for use in flooring or shock-absorbing mats, to name just one of many examples.