Adhesive Lamination

Merryweather Foam’s specialized adhesive lamination equipment employs pressure and heat to create permanent bonds between dissimilar products, facilitating the adhesive lamination process. This process involves feeding rolls of two or more different materials through large rollers under precise pressure and temperature conditions. In some instances, custom foam suppliers pre-apply a carefully selected adhesive to a material, ensuring optimal contact during the rolling process. Alternatively, adhesives may be evenly sprayed or rolled onto the materials as they unspool, ensuring thorough coating before entering the rolling area. The foam laminating part of the process enhances the bonding of foam materials with other substrates.

Following the lamination, the resulting composite material is spooled for further processing, allowing for customizations such as slitting to specified lengths and widths. Ultimately, the material produced through this adhesive lamination process embodies a fusion of the characteristics of each component material, creating a durable and versatile end product suitable for various manufacturing applications.

Adhesive Lamination Advantages

Adhesive lamination presents a versatile approach for combining materials with various characteristics, providing a tailored blend of properties. Merryweather Foam leverages efficient foam laminating techniques to provide custom foam solutions that enhance a diverse range of foam properties, including:
  • Density
  • Insulation
  • Flexibility
  • Sound absorption
  • Durability
  • Compressibility
  • Abrasion resistance
  • Breathability
  • Permeability
  • Solvent and chemical resistance
  • Buoyancy and weight
Appearance and aesthetics enhance the visual appeal of the final laminated foam product, contributing to its marketability. Merryweather Foam’s adhesive lamination provides options for addressing flammability and fire retardant specifications, further enhancing the safety and performance of the end product. Additionally, the foam lamination process ensures compliance with regulatory standards, including FDA, UL, and ULC approvals for specific industries or applications.

Leading Supplier of Adhesive Lamination Products

Merryweather Foam, a leading custom foam supplier, provides a vast array of adhesive lamination capabilities to serve the medical, industrial, automotive, and appliance industries. With over 1,000 foam materials available, we supply adhesive lamination products that offer unparalleled flexibility and customization options to meet the unique needs of our clients. We supply laminated foam products that serve as integral components in a myriad of applications, ranging from insulation panels to precision gasketing.

In the medical industry, where stringent standards for cleanliness and performance are paramount, laminated foam products – from surgical instruments to patient care devices – are engineered to withstand the rigors of medical environments while delivering optimal comfort and functionality. Our expertise in adhesive lamination ensures that medical professionals can trust the reliability and durability of our foam products.

Insulation panels, cushioning, and gaskets are among the top adhesive lamination products in the industrial sector, where efficiency and durability are essential. Additionally, we supply sheet stock with adhesive backing that enables easy and secure attachment of foam materials to various surfaces, facilitating streamlined production processes.

Automotive applications benefit greatly from our adhesive lamination products, where reliability and performance are non-negotiable. Whether it's sound absorption materials for noise reduction, foam gaskets for sealing applications, or interior trim components, our laminated foam products excel in meeting the stringent requirements of the automotive industry. Our commitment to quality and innovation ensures that automotive manufacturers can rely on our adhesive lamination solutions to deliver superior performance and durability.

Finally, in the appliance industry, where aesthetics and functionality converge, adhesive-laminated foam products offer versatile solutions for a wide range of applications. From vibration dampening pads to insulation panels, laminated foam materials provide essential support to ensure the efficiency and longevity of household appliances. With our expertise in adhesive lamination, we empower appliance manufacturers to enhance the performance and reliability of their products while meeting the evolving demands of consumers.

Common Materials Used in Adhesive Lamination

Our experts at Merryweather Foam will help you determine which foam material offers the properties needed to ensure superior performance for your specific application. Among our arsenal of foam materials, we commonly use microcellular urethane (Poron) with adhesive for precision gasketing applications, ensuring reliable seals in critical environments. For insulation panels demanding superior thermal performance, we often turn to crosslinked PE, offering exceptional insulation properties ideal for a myriad of industrial and commercial settings.

In applications requiring enhanced filtration and absorbency, we often rely on reticulated foam, prized for its open-cell structure and high porosity. From dish sponges to surgical filtration vacuums, reticulated foam delivers unparalleled performance, effectively trapping particles and ensuring clean, sterile environments.

Expanded PE also proves indispensable in manufacturing custom packaging inserts, where durability and cushioning properties are paramount. Expanded PE provides reliable protection for delicate items during transit, safeguarding against impact and vibration.

We are committed to tailoring laminated foam solutions to meet the unique demands of each application. With Merryweather Foam as your trusted partner, you can expect unparalleled expertise, quality craftsmanship, and a dedication to exceeding your expectations.