Laminated Polyethylene Foam

If you need a manufactured product, that can take a beating, absorb sound, or keep the heat in or out, then, laminated polyethylene foam (PE) is the perfect material.

Laminated polyethylene foam takes anything you throw at it. Polyethylene, or closed cell, is a strong and resilient material with excellent shock absorption abilities.

Its chemical cross-lining, makes it rigid enough to be used in many ways without showing any wear or tear over time. Laminating the PE foam together creates endless options for thickness, colour, and density.

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What is Polyethylene Foam Used for?

Laminated PE foam is used in an array of applications, including packaging, construction, and automotive. It is prized for its durability, strength, and resistance to moisture. Laminated foam can also be printed on and die-cut into shapes, making it a versatile material for a wide range of products.

The unique properties of PE foam, or closed cell foam, allow it to be used for shock absorption, making it widely used in the packaging industry, buoyancy aids, thermal insulation, camping mats, soundproofing, and more. It is truly one of the most versatile types of laminations on the market.

Adhesive and non-adhesive Polyethylene Foam is often your choice for packaging, joining, mounting, gasketing, and sealing irregular surfaces.

Polyethylene Foam (PE Foam) has an excellent dimensional stability and recovery capability that provides optimal cushioning protection against impact. It is suitable for cushion packaging, and it is used in many applications such as computer, automotive, constriction, and recreation products.

Ideally suited as a component material in products that require a shock absorption, dampening, vibration, insulation, barrier and/ or buoyancy component.

Applications of Laminated Polyethylene Foam

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Premier Polyethylene Foam Specialists

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Is PE Foam Strong?

Polyethylene Foam (PE Foam) is strong and resilient, with a smooth finish. This is because of the fine-celled, chemical cross-linked closed-cell foam.

This closed-cell foam padding is suitable for shock absorbing products such as shock-absorbing products, which is also a great way to dampen vibration. Closed-cell polyethylene foam has a variety of applications in furniture, Automotive, marine, and many other industries.

PE foam has superior thermal properties and is generally firmer than its EVA equivalent, making it a popular choice where hardness and cost-effectiveness are the most important. PE's low thermal conductivity provides excellent heat resistance, making it a suitable insulating material for walls, ceilings, and roofs.

PE foams have a variety of applications including sports equipment and packaging, soundproofing, and insulation. Polyethylene foam remains the choice material for many applications, that put a premium on cost-effectiveness over durability. Examples of this can include packaging, Carpet Underlays, car seats, car door panels, and luggage lining.

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Learn more about Polyethylene Foam (PE Foam)...

When used in a solid form, polyethylene foam is non-toxic. However, it tends to be toxic when it is in a liquid or vapour form. This is usually during the manufacturing process.

Polyethylene foam requires minimal maintenance and is expected to last 10 years or more in a typical indoor application. In most applications, the insulation will last the life of the mechanical piping system.

Polyethylene foam is a denser closed-cell foam that is known for its firmness and resistance to hydrolysis (will not break down when exposed to moisture and water). This is due-to the walls of the cells within the materials that are closed off, preventing air and water from flowing through them.

Polyethylene is a great candidate for food packaging. It can be used to make a soft-landing conveyor belt, which can be used for transporting fruit and vegetables.

In its solid form, PE foam is non-toxic to humans, making it extremely safe for food packaging. 

Polyethylene foam is relatively hard, as it is a low-density closed-cell foam that can be easily fabricated and flexible. This makes it ideal for packaging as it repels shock energy with a bounce, compared to the softer, open-cell foam of Polyurethane, which distributes shock on a broader scale. 

The best thickness for PE foam will depend on the intended application. For example, packaging that requires thinner foam should range from 1.5 mm to 3 mm while thicker foams used for heavier and fragile items will be around 12.5 mm. 

The three types of foam lamination include: 

Flame lamination: This involves exposing a piece of material to an open flame. This then creates a layer of molten polymer on the surface. This type does not require any adhesive and works best when bonding layers of foam to non-woven fabrics. 

Infrared lamination: This process also creates a thin layer of molten polymer on the surface of the material and doesn’t require any adhesive. The infrared process creates durable laminated foam-based products and is ideal for applications in the automotive industry. 

Hot melt: This process is different as it needs an adhesive to work but benefits from the end material forming quickly as it solidifies as soon as the adhesive has cooled.  

The closed cell structure of the polyethylene foam makes it incredibly moisture-resistant and non-absorbent. To ensure that it is fully waterproof, higher-density sheets must be used and then laminated.

Polyethylene (PE) is one of the most common types of plastic and is used to create various plastic products, such as water bottles, shopping bags, drainpipes, milk cartons, plastic wrap, and more. 

Since Polyethylene (PE) is classified as class 4, this means it is 100% recyclable. To handle PE foam effectively, recycling companies are now using modern recycling machines.

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