Hot Melt PUR Roll Coating System for Flat Lamination - Hybond

INTRODUCTION

The Hybond team possess a wealth of practical experience and expertise regarding the industrial bonding method of roll coating. We regularly work with customers to either aid them in making the change from labour intensive manual bonding alternatives, or to maintain and enhance roll coating systems they have in operation.

Please visit our website for more information on this topic.

Explore here one of Hybond’s most popular roll coating methods; a hot melt PUR roll coating system.
Contact Hybond today if we can be of assistance with this, or any of your company’s bonding processes.
All application systems demonstrated below can be provided by Hybond’s dedicated Machine Systems Division.

WHAT IS ROLL COATING?

Quite simply put, roll coating machinery allows the operator to apply hot melt or cold glue adhesives to a variety of flat sheet substrates both evenly and efficiently via a series of automated rollers.
This post focuses on the particular benefits of a hot melt PUR roll coating system.

WHO MIGHT CARRY OUT THIS BONDING PROCESS?

This is a popular bonding method used within many industries such as:

MANUAL APPLICATION METHODS – WHY MAKE THE CHANGE?

Here are two popular manual adhesive application techniques for those carrying out forms of flat lamination:

DISADVANTAGES OF MANUAL APPLICATION

Time consuming

Labour intensive

Large adhesive volumes required

Requiring 2-side coverage (contact adhesive)

Requiring lengthy static press time

THE MANY BENEFITS OF A HOT MELT PUR ADHESIVE SYSTEM

At Hybond, we favour a hot melt PUR roll coating system due to the many benefits provided by both the PUR adhesive, and its application system. We explore the advantages of both below.

PUR FOR FLAT LAMINATION

So what is a PUR hot melt adhesive and how does it differ from standard hot melts?
Polyurethane reactive hot melts are know as reactive adhesives because their curing process is activated by moisture. Moisture present in the air and/or the bonded substrate creates a chemical reaction which produces a fast, non-toxic, incredibly strong bond with many advantages such as:

• Continuous production process
• No static press time required
• Ultimate mechanical bonding strength
• Excellent water resistance
• Warp-free bond line
• High heat resistance
• Outstanding cold resistance
• Excellent creep resistance

PUR MELTING EQUIPMENT

The main feature in processing polyurethane hot melts efficiently is the use of correctly designed application equipment. The equipment differs from typical hot melt applicators due to the moisture sensitive behaviour of polyurethane hot melts.

Take a look here at an example of a typical PUR application line which Hybond’s Machine Systems Division would provide to a manufacturer carrying out flat lamination. This line features a hot melt roll coater device, and the operator benefits from: Versatile set-up, Easy maintenance, Simplicity of use, No static press time.

You will get efficient and thoughtful service from Jiwei.

Hybond Machine Systems PUR Application Line

FUTURE-PROOF, MODULAR SYSTEMS

The beauty of a Hybond Machine System’s installation such as the example given above, is that it is entirely modular; bespoke to the customer’s needs. The line can be enlarged or reduced dependent on requirements, and central to it all is the highly intelligent PLC control station. This clever unit is fully equipped to control a wide variety of popular components and functions, such as robotics, saws, automated in-feeds, out-feeds / automated stacking and much more. The ability to grow application lines with ease to support growing production demands, means that Hybond solutions are truly future-proof solutions.

HYBOND AND YOUR EXISTING LINE

If your manufacturing operation is already carrying out the processes described above or similar, Hybond have a great deal to offer via our highly skilled technical team, and the resources within the comprehensively equipped Hybond Laboratory. Hybond can assist in: streamlining, troubleshooting, enhancing, servicing and more. Our technical team are available for site visits and equipment audits, but can also carry out detailed adhesive testing in our dedicated technical showroom facility resulting in zero disruption to your production location. Take a look below at just some of the solutions and services we provide those carrying out hot melt PUR roll coating:

From handy solutions such as the retro-fitting of infrared devices to the in-feed and out-feeds of roll coaters, eliminating the complications that arise from cold ambient temperatures, to detailed analysis in the Hybond Laboratory; the Hybond team work hand in hand with manufacturers to ensure optimum quality, repeatability, and efficiency in their flat laminating processes.

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.

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 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 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.

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!

Click here for the contact form!

The following brochures provide information about our products.

The company is the world’s best PUR for Flat Lamination supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.