Lamination

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Simulated flight (using image stack created by µCT scanning) through the length of a knitting needle that consists of laminated wooden layers: the layers can be differentiated by the change of direction of the wood's vessels
Shattered windshield lamination keeps shards in place Autoglas gesplittert 01.jpg
Shattered windshield lamination keeps shards in place
Laminate flooring Laminaat.jpg
Laminate flooring
A flexible thin-film solar cell for aerospace use (2007) Aerospace Product-Flexible Thin-Film Solar PV-United Solar Ovonic.jpg
A flexible thin-film solar cell for aerospace use (2007)

Lamination is the technique/process of manufacturing a material in multiple layers, so that the composite material achieves improved strength, stability, sound insulation, appearance, or other properties from the use of the differing materials, such as plastic. A laminate is a permanently assembled object created using heat, pressure, welding, or adhesives. [1] Various coating machines, machine presses and calendering equipment are used.

Contents

Materials

There are different lamination processes, depending primarily on the type or types of materials to be laminated. The materials used in laminates can be identical or different, depending on the process and the object to be laminated.

Textile

Laminated fabric are widely used in different fields of human activity, including medical and military. [2] :148 Woven fabrics (organic and inorganic based) are usually laminated by different chemical polymers to give them useful properties like chemical resistance, dust, grease, windproofness, photoluminescence (glowing and other light-effects e.g. in high-visibility clothing), tear strength, stiffness, thickness etc. [3] [2] :2,16,18 Coated fabrics may be considered as a subtype of laminated fabrics. [2] :1 Nonwoven fabrics (e.g. fiberglass) are also often laminated. According to a 2002 source, the nonwovens fabric industry was the biggest single consumer of different polymer binding resins. [2] :16

Materials used in production of coated and laminated fabrics are generally subjected to heat treatment. [2] :32 Thermoplastics and thermosetting plastics (e.g. formaldehyde polymers) are equally used in laminating and coating textile industry. [2] :32 In 2002 primary materials used included polyvinyl acetate, acrylics, polyvinyl chloride (PVC), polyurethanes, and natural and synthetic rubbers. [2] :33 Copolymers and terpolymers were also in use. [2] :33

Thin-films of plastics were in wide use as well. Materials varied from polyethylene and PVC to kapton depending on application. In automotive industry for example the PVC/acrylonitrilebutadiene-styrene (ABS) mixtures were often applied for interiors by laminating onto a polyurethane foam to give a soft-touch properties. [2] :42 Specialty films were used in protective clothing, .e.g. polytetrafluoroethylene (PTFE), polyurethane etc. [2] :42

Glass

Plastic film can be used to laminate either side of a sheet of glass. Vehicle windshields are commonly made as composites created by laminating a tough plastic film between two layers of glass. This is to prevent shards of glass detaching from the windshield in case it breaks.

Wood

Plywood is a common example of a laminate using the same material in each layer combined with epoxy. Glued and laminated dimensional timber is used in the construction industry to make beams (glued laminated timber, or Glulam), in sizes larger and stronger than those that can be obtained from single pieces of wood. Another reason to laminate wooden strips into beams is quality control, as with this method each and every strip can be inspected before it becomes part of a highly stressed component.

Examples of laminate materials include melamine adhesive countertop surfacing and plywood. [4] Decorative laminates and some modern millwork components are produced with decorative papers with a layer of overlay on top of the decorative paper, set before pressing them with thermoprocessing into high-pressure decorative laminates (HPDL). [5] A new type of HPDL is produced using real wood veneer or multilaminar veneer as top surface.[ citation needed ] High-pressure laminates consists of laminates "molded and cured at pressures not lower than 1,000 lb per sq in.(70 kg per cm2) and more commonly in the range of 1,200 to 2,000 lb per sq in. (84 to 140 kg per cm2). [6] Meanwhile, low pressure laminate is defined as "a plastic laminate molded and cured at pressures in general of 400 pounds per square inch (approximately 27 atmospheres or 2.8 × 106 pascals). [7]

Paper

A paper sign that has been laminated so it could be used outdoors Smithsonian Folklife Festival 2011 - PARTICIPANT HOSPITALITY.JPG
A paper sign that has been laminated so it could be used outdoors

Corrugated fiberboard boxes are examples of laminated structures, where an inner core provides rigidity and strength, and the outer layers provide a smooth surface. A starch based adhesive is usually used.

Laminating paper products, such as photographs, can prevent them from becoming creased, faded, water damaged, wrinkled, stained, smudged, abraded, or marked by grease or fingerprints. Photo identification cards and credit cards are almost always laminated with plastic film. Boxes and other containers may be laminated using heat seal layers, extrusion coatings, pressure sensitive adhesives, UV coating, etc.

Lamination is also used in sculpture using wood or resin. An example of an artist who used lamination in his work is the American Floyd Shaman.

Laminates can be used to add properties to a surface, usually printed paper, that would not have them otherwise, such as with the use of lamination paper. Sheets of vinyl impregnated with ferro-magnetic material can allow portable printed images to bond to magnets, such as for a custom bulletin board or a visual presentation. Specially surfaced plastic sheets can be laminated over a printed image to allow them to be safely written upon, such as with dry erase markers or chalk. Multiple translucent printed images may be laminated in layers to achieve certain visual effects or to hold holographic images. Printing businesses that do commercial lamination keep a variety of laminates on hand, as the process for bonding different types is generally similar when working with thin materials.

Paper is normally laminated on particle or fiberboards giving a good-looking and resistant surface for use as furniture, decoration panels and flooring. [8]

Paper laminations are also used in packaging. For example, juiceboxes are fabricated from liquid packaging board which is usually six layers of paper, polyethylene, and aluminum foil. Paper is used in the lamination to shape the product and give the juicebox an extra source of strength.

The base is most often particle- or fiberboards, then some layers of absorbent kraft paper. The last layers are a decor paper covered with an overlay. The lamination papers are covered with an inert resin, often melamine, which is cured to form a hard composite with the structure of paper. The laminates may also have a lining on the back side of laminating kraft to compensate for the tension created by the top side lamination. Cheaper particle boards may have only a lining of laminating kraft to give surface washability and resistance to wear.

The decor paper can also be processed under heat and low/high pressure to create a melamine laminated sheet, that has several applications. The absorbent kraft paper is a normal kraft paper with controlled absorbency, which means a high degree of porosity. It is made of clean low kappa hardwood kraft with good uniformity. The grammage is 80 - 120 g/m2 and normally 2-4 plies are used. [8] The decor paper is the most critical of the lamination papers as it gives the visual appearance of the laminate. The impregnation resin and cellulose have about the same refraction index which means that the cellulose fibers of the paper appear as a shade and only the dyestuffs and pigments are visible. Due to this the decor paper demands extreme cleanness and is produced only on small paper machines with grammage 50 - 150 g/m2. [8] The overlay paper have grammage of 18 – 50 m2 and is made of pure cellulose, thus it must be made of well delignified pulp. It becomes transparent after impregnation letting the appearance of the decor paper come through. The laminating kraft have a grammage of 70 - 150 g/m2 and is a smooth dense kraft paper. [8]

Metal

Electrical equipment such as transformers and motors usually use an electrical steel laminate coatings to form the core of the coils used to produce magnetic fields. The thin lamination reduces the power loss due to eddy currents. Fiber metal laminate is an example of thin metal laminated by, a glass fiber-reinforced and epoxy-glued sheets.

Microelectronics

Lamination is widely used in production of electronic components such as PV solar cells. [9]

Film types

Laminate plastic film is generally categorized into these five categories:

See also

Related Research Articles

<span class="mw-page-title-main">Adhesive</span> Non-metallic material used to bond various materials together

Adhesive, also known as glue, cement, mucilage, or paste, is any non-metallic substance applied to one or both surfaces of two separate items that binds them together and resists their separation.

<span class="mw-page-title-main">Corrugated fiberboard</span> Composite paper material

Corrugated fiberboard, corrugated cardboard, or corrugated is a type of packaging material consisting of a fluted corrugated sheet and one or two flat linerboards. It is made on "flute lamination machines" or "corrugators" and is used for making corrugated boxes. The corrugated medium sheet and the linerboard(s) are made of kraft containerboard, a paperboard material usually over 0.25 millimetres (0.01 in) thick.

<span class="mw-page-title-main">Thermosetting polymer</span> Polymer obtained by irreversibly hardening (curing) a resin

In materials science, a thermosetting polymer, often called a thermoset, is a polymer that is obtained by irreversibly hardening ("curing") a soft solid or viscous liquid prepolymer (resin). Curing is induced by heat or suitable radiation and may be promoted by high pressure or mixing with a catalyst. Heat is not necessarily applied externally, and is often generated by the reaction of the resin with a curing agent. Curing results in chemical reactions that create extensive cross-linking between polymer chains to produce an infusible and insoluble polymer network.

<span class="mw-page-title-main">Paperboard</span> Thick paper-based material

Paperboard is a thick paper-based material. While there is no rigid differentiation between paper and paperboard, paperboard is generally thicker than paper and has certain superior attributes such as foldability and rigidity. According to ISO standards, paperboard is a paper with a grammage above 250 g/m2, but there are exceptions. Paperboard can be single- or multi-ply.

<span class="mw-page-title-main">Whiteboard</span> Surface for nonpermanent markings

A whiteboard is a glossy, usually white surface for making non-permanent markings. Whiteboards are analogous to blackboards, but with a smoother surface allowing for rapid marking and erasing of markings on their surface. The popularity of whiteboards increased rapidly in the mid-1990s and they have become a fixture in many offices, meeting rooms, school classrooms, public events and other work environments.

<span class="mw-page-title-main">Particle board</span> Pressed and extruded wood product

Particle board, also known as particleboard, chipboard, and low-density fiberboard, is an engineered wood product manufactured from wood chips and a synthetic resin or other suitable binder, which is pressed and extruded. Particle board is often confused with oriented strand board, a different type of fiberboard that uses machined wood flakes and offers more strength.

Arborite is the leading Canadian manufacturer of high-pressure decorative plastic laminates (HPL). Best known as a counter top surfacing material, this laminate is a durable decorative veneer applied to cabinetry, furniture, and other horizontal and vertical surfaces. The original Arborite material was developed in 1942 by the Howard Smith Paper Company as an innovative way to utilize waste by-products of the Canadian papermaking industry, and to this day any laminate used for the same purpose is commonly referred to in Canada by the trade name Arborite.

Micarta is a brand name for composites of linen, canvas, paper, fiberglass, carbon fiber, or other fabric in a thermosetting plastic. It was originally used in electrical and decorative applications. Micarta was developed by George Westinghouse at least as early as 1910 using phenolic resins invented by Leo Baekeland. These resins were used to impregnate paper and cotton fabric which were cured under pressure and high temperature to produce laminates. In later years this manufacturing method included the use of fiberglass fabric, and other resin types were also used. Today Micarta high-pressure industrial laminates are produced with a wide variety of resins and fibers. The term has been used generically for most resin impregnated fiber compounds. Common uses of modern high-pressure laminates include electrical insulators, printed circuit board substrates, and knife handles.

<span class="mw-page-title-main">Countertop</span> Horizontal work surface

A countertop, also counter top, counter, benchtop, worktop or kitchen bench, bunker is a raised, firm, flat, and horizontal surface. They are built for work in kitchens or other food preparation areas, bathrooms or lavatories, and workrooms in general. The surface is frequently installed upon and supported by cabinets, positioned at an ergonomic height for the user and the particular task for which it is designed. A countertop may be constructed of various materials with different attributes of functionality, durability and aesthetics, and may have built-in appliances, or accessory items relative to the intended application.

<span class="mw-page-title-main">Fiberboard</span> Engineered wood product made out of wood fibers

Fiberboard or fibreboard is a type of engineered wood product that is made out of wood fibers. Types of fiberboard include particle board or low-density fiberboard (LDF), medium-density fiberboard (MDF), and hardboard or high-density fiberboard (HDF).

<span class="mw-page-title-main">Nonwoven fabric</span> Sheet of fibers

Nonwoven fabric or non-woven fabric is a fabric-like material made from staple fibre (short) and long fibres, bonded together by chemical, mechanical, heat or solvent treatment. The term is used in the textile manufacturing industry to denote fabrics, such as felt, which are neither woven nor knitted. Some non-woven materials lack sufficient strength unless densified or reinforced by a backing. In recent years, non-wovens have become an alternative to polyurethane foam.

Coated paper is paper that has been coated by a mixture of materials or a polymer to impart certain qualities to the paper, including weight, surface gloss, smoothness, or reduced ink absorbency. Various materials, including kaolinite, calcium carbonate, bentonite, and talc, can be used to coat paper for high-quality printing used in the packaging industry and in magazines.

<span class="mw-page-title-main">Laminated glass</span> Type of safety glass with a thin polymer interlayer that holds together when shattered

Laminated glass is a type of safety glass consisting of two or more layers of glass with one or more thin polymer interlayers between them which prevent the glass from breaking into large sharp pieces. Breaking produces a characteristic "spider web" cracking pattern when the impact is not enough to completely pierce the glass.

<span class="mw-page-title-main">Melamine resin</span> Hard, thermosetting plastic material often used in dinnerware

Melamine resin or melamine formaldehyde is a resin with melamine rings terminated with multiple hydroxyl groups derived from formaldehyde. This thermosetting plastic material is made from melamine and formaldehyde. In its butylated form, it is dissolved in n-butanol and xylene. It is then used to cross-link with alkyd, epoxy, acrylic, and polyester resins, used in surface coatings. There are many types, varying from very slow to very fast curing.

<span class="mw-page-title-main">Adhesive tape</span> Strip of material backed with adhesive

Adhesive tape is one of many varieties of backing materials coated with an adhesive. Several types of adhesives can be used.

Extrusion coating is the coating of a molten web of synthetic resin onto a substrate material. It is a versatile coating technique used for the economic application of various plastics, notably polyethylene, onto paperboard, corrugated fiberboard, paper, aluminium foils, cellulose, Non-wovens, or plastic films.

A thermoset polymer matrix is a synthetic polymer reinforcement where polymers act as binder or matrix to secure in place incorporated particulates, fibres or other reinforcements. They were first developed for structural applications, such as glass-reinforced plastic radar domes on aircraft and graphite-epoxy payload bay doors on the Space Shuttle.

Vacuum bag moulding is the primary composite manufacturing process for producing laminated structures. It is common in the aerospace industry.

The wet strength of paper and paperboard is a measure of how well the web of fibers holding the paper together can resist a force of rupture when the paper is wet. Wet strength is routinely expressed as the ratio of wet to dry tensile force at break.

<span class="mw-page-title-main">Decorative laminate</span> Laminated composite material primarily used as a finish for furniture and wall panels

Decorative laminates are laminated products primarily used as furniture surface materials or wall paneling. It can be manufactured as either high- or low-pressure laminate, with the two processes not much different from each other except for the pressure applied in the pressing process. Also, laminate can be produced either in batches or in a continuous process; the latter is called continuous pressure laminate (CPL).

References

  1. Carter, Richard. "Method of laminating multiple layers". Google Patents. Retrieved 15 February 2015.
  2. 1 2 3 4 5 6 7 8 9 10 Fung, Walter (2002). Coated and laminated textiles. Textile Institute. Boca Raton, FL: CRC Press. ISBN   1-59124-756-X. OCLC   57250766.
  3. Fung, W. (9 May 2002). Coated and Laminated Textiles | ScienceDirect. Woodhead. ISBN   9781855735767 . Retrieved 2021-11-26.
  4. Martin, Alan; Harbison, Sam; Beach, Karen; Cole, Peter (2012-03-30). An Introduction to Radiation Protection 6E. CRC Press. ISBN   9781444146073.
  5. "What Is Post-Formed Plastic Laminate?". Delorie Countertops and Doors. 21 January 2015. Retrieved 15 February 2015.
  6. McGraw-Hill Dictionary of Architecture & Construction
  7. McGraw-Hill Dictionary of Scientific & Technical Terms, 6E, Copyright © 2003 by The McGraw-Hill Companies, Inc.
  8. 1 2 3 4 Paulapuro, Hannu (2000). "5". Paper and Board grades. Papermaking Science and Technology. Vol. 18. Finland: Fapet Oy. pp. 108–111. ISBN   952-5216-18-7.
  9. Steim, R.; Chabrecek, P.; Sonderegger, U.; Kindle-Hasse, B.; Siefert, W.; Kroyer, T.; Reinecke, P.; Lanz, T.; Geiger, T.; Hany, R.; Nüesch, F. (2015-05-11). "Laminated fabric as top electrode for organic photovoltaics". Applied Physics Letters. 106 (19): 193301. Bibcode:2015ApPhL.106s3301S. doi: 10.1063/1.4919940 . ISSN   0003-6951. S2CID   119779721.