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The benefits of reactive PUR hotmelts in surface lamination

Surface lamination is a process used in various industry sectors to bond plastic films, decor papers, HPL, CPL, etc., to the surfaces of different materials.

Furniture manufacturers and furniture suppliers typically laminate MDF and chipboard panels as well as lightweight panels (sandwich elements) made from plastic and aluminium. Sandwich elements are often laminated to make pieces of furniture, car parts, and in ship and boat building.

Decor papers are made of plastics, natural fibres, and varnished systems, and available in all kinds of designs, with and without embossments, and in different qualities. There is a huge choice of laminated boards available for furniture elements and flooring.
The adhesive joins the decor and the carrier material, and therefore plays a key role in the quality of the surface lamination. Kitchen and bathroom fittings, for instance, are constantly exposed to heat and moisture, but expected to have a long service life. Floors also have to withstand mechanical wear and tear over many years. The choice of adhesive impacts both the quality and durability of the lamination. Reactive polyurethane adhesives have revolutionized surface lamination and opened up a multitude of new opportunities.

EVA and PVAc glues are great for a wide range of applications, but not the product of choice for surface lamination.

Reactive PUR hotmelts are far more suitable for this purpose. They enable an unprecedented variety of base material and decor combinations, produce stronger and more resistant bonds, and contribute to efficient production processes. This opens up new markets to many manufacturers.

PUR adhesives bond to various materials and allow numerous material combinations to be surface laminated

EVA and PVAc adhesives have a high water content, so the carrier material has to be absorbent in some way. This limits their scope of use to a certain degree. Wood-based materials are generally very absorbent, while plastics and metals are not. Reactive PUR adhesives do not contain any water and have excellent bonding properties to several materials, such as wood-based and mineral materials and plastics.

Reactive PUR hotmelts provide second to none surface lamination quality

Water-based adhesives can cause irreversible swelling of the decor surface, which is particularly undesirable for high-gloss decors – any unevenness impacts the super-smooth mirror effects. This will not happen when using PUR adhesives. Once the glue has hardened, the adhesive layer will not distort in any way.

Reactive PUR hotmelts produce the best results for surface lamination

EVA and PVAc glues have only limited resistance to strong temperature fluctuations and moisture, so the glue joints will begin to deteriorate over time. Reactive PUR hotmelts, however, react chemically to form a tightly cross-linked elastomer or duromer, which creates an immensely strong and durable bond. Reactive PUR hotmelts currently generate the best and most long-lasting adhesive bonds possible.

Reactive PUR hotmelts are customizable and contribute to efficient production processes

Streamlined manufacturing processes are key to the industry. Laminating machines that use PVAc or EVA adhesives have relatively long cycle times, or need complex process technology to keep cycle times short. The laminated materials can only move on to the next processing stage once all the moisture has evaporated from the glue joint and/or the glue has formed its film.

This is where the benefits of reactive PUR hotmelts shine through. Short cycle times and direct further processing of the laminated material contribute to efficient processes. The high initial strength of a PUR adhesive and easy application with heated rollers and slot nozzles also speed up the manufacturing process. These methods require customizable PUR hotmelts. Depending on the material combination and process technology, the formulation of the adhesive can be adjusted to production specifications such as the application temperature, melting viscosity, open time, and the initial and final strength.

Surface lamination with low-emission PUR hotmelt adhesives (hotmelts)

The demand for low-emission adhesive systems has risen sharply in recent years. In the area of surface lamination, low-emission PUR adhesives offer a whole range of advantages. In contrast to conventional reactive PUR hotmelt adhesives, low-emission variants offer the following advantages:

  • Identical bonding properties

  • Safe and easy handling

  • Environmentally friendly manufacturing process

  • No labeling requirement

  • More cost-effective flat lamination systems due to simplified extraction systems

Surface lamination with bio-based hotmelts

KLEIBERIT has a long tradition of intensive research and development. We are committed to producing more sustainable products and we have invested considerable research into reactive PUR adhesives containing plant-based and sustainable raw materials that are not suitable for food production. Users can therefore expect the same level of quality in surface lamination – i.e. excellent bonding performance and coordinated production processes – as our conventional reactive PUR hotmelts provide. With the right know-how, it is possible to reduce the level of petroleum-based raw materials used.

Are you looking to optimize your surface laminating processes?

An effective laminating process requires the application method and the adhesive to be configured to each other in the best possible way. Our engineers have decades of experience with various adhesive systems, application technologies and industry standard equipment. Contact us for advice!

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