Widely speaking, laminating is when manufacturers bond two different surfaces. Manufacturers can laminate all sorts of materials, including the one we're covering on this page, foam. In this context, we're talking about laminating thermoplastic foam, such as those made from EVA, polypropylene, polyethylene, PVC, urethane, and cross-link foam, among others. When manufacturers laminate foams like these, they alter their density, stability and makeup.
Laminated foam products are popular in a wide variety of industries, such as: sports and recreation, military, marine, flooring, HVAC, healthcare and rehab, electronics, consumer products, automotive manufacturing, appliance and aerospace engineering. Within these industries, they serve applications related to gas and liquid containment, cushioning, support, sound blocking and heat resistance. Some of the many products you can make with laminating foam include: truck liners, interior vehicle fender panels, footwear, specialized garments, foam surfaces, positioners, professional displays, sound barrier wall panels, stretcher pads and wheelchair cushions.
There are many different ways of laminating foam, including via: heat preparation, flame foam lamination, adhesive lamination and corona treating. Of these, the most common are flame foam lamination and adhesive lamination. During flame foam lamination, manufacturers pass the foam over an open flame in order to a thin layer of molten polymer on its surface to which they can bond a substrate. To do so, they put the two in contact and apply pressure. Adhesive lamination involves the use of bonding agents, like pressure sensitive adhesive (PSA). To bond the foam and the substrate, manufacturers either apply the bonding agents directly to the surfaces, or they apply them indirectly via transfer tapes, which are pre-coated release liners. To accomplish laminating, manufacturers use all sorts of laminating machines, including: roll laminating machinery, hand fed laminators, automatic laminators, cold laminators, pouch laminators and flame laminators.
To customize your laminated foam design, your manufacturer can add custom prints, create a gloss, matte or sticky finish, and work with foam of different lengths, widths and thicknesses. To learn more about how laminating foam may benefit your application, reach out to a knowledgeable supplier today. To help you get started, we’ve provided a comprehensive list of high quality companies on this page. Good luck!