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Foam Lamination all in one pack: What you need to know about Foam Lamination

2020-08-25

Ariaprene Foam lamination

What is foam lamination?

Foam lamination is a fabric surface modification technique often used to improve the structural or performance properties of a material. Lamination is used to waterproof materials and add protective coatings and is also often used to form a composite material – a combination of multiple materials. Laminated materials are often composed of at least two or more layers, including a polymeric, continuous layer, often a foam core. Foams can be combined and laminated with other foams, textiles, backings, and coatings. 

Where can I find foam lamination products?

You can find laminated foam materials commonly used in a variety of industries, including aerospace, military, construction, medical, and more. 

  • Automotive: seats, seat covers, soft touch surfaces, headliners, car seats, armrests, door cladding, floor mats, soundproofing, interior fender panels, bed liners
  • Medical: braces, supports, splints, slings, gaskets, sealings, orthotics, dressings, device attachments, wheelchair padding
  • Home: insulation, mattresses, weatherproofing, hoses, insulation, tubing, HVAC, hot tub covers
  • Soft goods: performance accessories, padded athletic gear, rain gear, wetsuits
  • Footwear: uppers, sleeves, pads, vent panels, tongues
  • Electronics: headphone padding, watch wristbands, soft-touch wearables,     
  • Sports: soft grips, sleeves, weighted wearables, protective equipment

 

Types of foam lamination

The most common types of foam laminations are adhesive lamination and flame lamination.

Adhesive lamination

Adhesive lamination requires a chemical adhesive or bonding agent. These can be made of pressure-sensitive adhesive or synthetic compounds such as polyurethane. Some types of adhesive foam lamination require a solvent for production. Heat is also used during the process to allow the adhesive to cure. The chemical adhesives can be used on both surfaces, or be pre-treated onto one of the liners, and then transferred during the manufacturing process.

Flame lamination

Flame lamination is very effective for bonding soft, flexible foams and non-woven to fabrics, but is also frequently used for papers and films. Flame lamination gets its namesake because foam is literally passed over a flame, resulting in a layer of melted polymer on the surface. A secondary layer of material is then quickly stretched and pressed over that thin, sticky polymer, creating a strong bond between the two materials. There is oftentimes less energy used during the manufacturing of an adhesive lamination process, because less heat is required, resulting in lowered manufacturing costs and environmental impact.

Water-based foam lamination

However, over the past decade, water-based foam lamination solutions have quickly become more popular for brands in a variety of industries. Tiong Liong Industrial Co. Ltd, the makers of Ariaprene®, started out as a foam lamination factory and perfected a proprietary solvent-free, water-based foam lamination process over years of development. Using toxin-free, hypoallergenic foams as a base, these layers are bonded together using a patented, eco-friendly foam lamination process, and is available for every custom Ariaprene® package. These closed-cell foam cores can be combined in a variety of thicknesses, colors, textures, perforations, and can be laminated with fabrics as well as PU foil to create a leather-like appearance and add waterproofing properties.

Know more about the advantages why should choose closed cell foam

Advantages of Foam Lamination?

ARIAPRNE® all product technologies are using water-based adhesive and Tiong Liong Corporation exclusive adhesive formula. The water-based adhesives is friendly to people skin and our environment as it is VOCs (Volatile Organic Compounds) Free.

ARIAPRENE® can laminate recycled polyester and nylon fabrics based on customers needs. Make the whole package even sustainable and build brands reputation.

Pricing for foam lamination

Oftentimes ARIAPRENE® is compared with other foam types, such as  PU foam (Polyurethane), EVA foam (Ethylene-vinyl acetate ), SBR (Styrene Butadiene Rubber), and Neoprene. Although each of these foam types has unique characteristics, generally speaking, prices of Ariaprene® foam-core fabric is competitive to Neoprene where a product is applicable, but a price higher than EVA foam and PU foam can be expected.

Prices of ARIAPRENE® foam-core fabric range from single-digit to beyond $20USD per yard, with widths of around 48 inches. Pricing can be quite varied because each ARIAPRENE® foam-core fabric package is customized to best fit product and design needs. Extra functions can be added to the foam-core package after face and lining fabric is chosen, including water-repellent or resistant properties, wicking, or antimicrobial add-ons.

ARIAPRENE® allows for a cleaner manufacturing process, as well as more design flexibility. Learn more about Ariaprene and get in touch with us today. 

More about ARIAPRENE® Foam Lamination

Check out ARIAPRENE® sample book for more colors, patterns, perforations and designs below:

ARIAPRENE® 2021 Sample book entry

ARIAPRENE® 2020 Sample book

 

Frequently Asked Questions About Foam Lamination

 

Q1:What is the purpose of lamination?

A1:Lamination is a process of bonding layers of materials together to improve strength, durability, and water resistance. It is commonly used in the production of outdoor gear, including backpacks, tents, and jackets. The purpose of lamination is to create a barrier that prevents moisture from penetrating the fabric while still allowing air to circulate.

 

Q2:Is Foam Lamination waterproof ?

A2:Foam lamination can provide water resistance, but it may not be completely waterproof. The level of water resistance depends on the type and thickness of foam used, as well as the lamination process. Additional coatings or treatments may be necessary to achieve full waterproofing.

 

Q3:Will foam melt in the laminator ?

A3:Foam can melt in the laminator if exposed to excessive heat or pressure. It is important to use the appropriate temperature and pressure settings when laminating foam to prevent melting and ensure successful lamination. Some types of foam may also be more heat-resistant than others and require different settings.

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2019-07-19

With the future of our planet in the hands of the humans who inhabit it, we all must do our part to make a change. AP Terra is a new line of materials made from recycled Ariaprene products. Terra is made in-house from up to 100% recycled Ariaprene material, ensuring our unused product is being repurposed correctly. By repurposing what would normally be considered waste, Terra reduces negative environmental impact and helps reduce our carbon footprint.