Process

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.

One of the primary advantages of flame lamination is that no adhesive is needed. In addition to cost savings, avoiding the use of adhesives eliminates the risk of adhesive creep and bond failure, and the materials are easier to recycle. For some composites, a very thin layer of foam can be used as a bonding agent between two materials, taking advantage of the desirable characteristics of flame lamination, without adding any appreciable thickness.

Used most often in conjunction with open-cell polyurethane foams, including both polyester and polyether, flame laminating applies flawlessly to numerous soft goods applications, such as orthopedic padding, thermal insulation components, acoustic insulation products and automotive interior components.