Flame lamination is used to produce laminates by bonding foam/fabric or foam/film by passing the foam over an open flame. Exposure to the flame creates a thin layer of molten polymer on the foam surface, which is then brought into contact with the secondary layer under pressure to develop a bond between the two surfaces.
Flame lamination was developed in Europe in the late 1950’s and with modern technologies in web handling, computerized drive systems, and in-line inspection, flame lamination continues today to be an important technology for the lamination of variety of textiles (knits, wovens, nonwovens) to foams, films, and other substrates for the automotive, medical, and industrial markets.
As its name suggest, Flame lamination involves passing a substrate (primarily polyurethane foam) through a controlled flame changing the surface of the foam to a molten state. Another substrate (textile) is then brought into direct contact with the molten foam under controlled tension and pressure (nip point). As the molten foam rapidly cools, a cohesive bond is formed at the interface between the foam and textile. There are many factors that control the amount of bond strength achieved between the foam and the substrate including the speed and distance at which the foam passes through the controlled flame.
From car seats to foot insoles, composite materials created through Flame lamination are as varied as they are numerous. Automotive soft trim interior materials such as automotive headliner, seating, and door panel applications are largely derived from composite materials flame laminated. Orthopedic braces, sound attenuation materials, footwear components, and many other composite materials are the result of the flame lamination process.
PONSE offers flame lamination in its West Bridgewater, MA, Port Huron, MI and Clinton, TN locations. With state of the art flame lamination lines engineered and built in-house, PONSE is the industry leader in engineered foam composites and other flexible composite materials.
For more information regarding flame lamination please contact PONSE Zoe at +86 15205104071 or firstname.lastname@example.org