LAMINATION OF PAPER WITH LAMINATION OF PAPER WITH PLASTICPLASTIC

A A laminatelaminate is a material that can be  is a material that can be constructed by uniting two or more constructed by uniting two or more layers of material together. The layers of material together. The process of creating a laminate process of creating a laminate is is laminationlamination, which in common , which in common parlance refers to the placing of parlance refers to the placing of something between layers of plastic something between layers of plastic and gluing them with heat and/or and gluing them with heat and/or pressure, usually with an adhesive.pressure, usually with an adhesive.

In electrical engineering, lamination In electrical engineering, lamination

is a construction technique used to is a construction technique used to

reduce unwanted heating effects reduce unwanted heating effects due due

to to eddy currentseddy currents in components,  in components,

such as the such as the Magnetic Magnetic

corescores of transformers. Decorative  of transformers. Decorative

plastic laminate is a durable flat plastic laminate is a durable flat

sheeting material used in home and sheeting material used in home and

industrial furnishings.industrial furnishings.

Decorative laminate is commonly used to Decorative laminate is commonly used to

surface kitchen counters, table tops, and surface kitchen counters, table tops, and

cabinetry because of its resistance to cabinetry because of its resistance to

stains, scratches, and heat. The laminate stains, scratches, and heat. The laminate

sheets are made up of three layers: the sheets are made up of three layers: the

bottom layer of brown paper coated with bottom layer of brown paper coated with

phenolic resin, a second layer of paper phenolic resin, a second layer of paper

decorated with the desired pattern, and a decorated with the desired pattern, and a

third layer of clear sheetthird layer of clear sheet. .

There are different lamination processes, There are different lamination processes, depending on the type of materials to be depending on the type of materials to be laminated. The materials used inlaminated. The materials used inlaminates can be the same or different, laminates can be the same or different, depending on the processes and the depending on the processes and the object to be laminated. An example of the object to be laminated. An example of the type of laminate using different materials type of laminate using different materials would be the application of a layer would be the application of a layer of plastic film — the "laminate" — on of plastic film — the "laminate" — on either side of a sheet of glass —either side of a sheet of glass —the the laminatedlaminated subject. subject.

Plastic laminate was first used as an Plastic laminate was first used as an insulating material for industrial products. insulating material for industrial products. Laminating paper, such as photographs, can Laminating paper, such as photographs, can prevent it from becoming creased, sun prevent it from becoming creased, sun damaged, wrinkled, stained, smudged, damaged, wrinkled, stained, smudged, abraded and/or marked by grease, abraded and/or marked by grease, fingerprints and environmental fingerprints and environmental concerns. Photo identification cards concerns. Photo identification cards and credit cards are almost always and credit cards are almost always

laminated laminated with plastic film. Boxes and other containers with plastic film. Boxes and other containers are also laminated using a UV coating. are also laminated using a UV coating. Lamination is also used in sculpture using Lamination is also used in sculpture using wood or resin.wood or resin.

Decorative plastic laminate sheeting is mode of resins Decorative plastic laminate sheeting is mode of resins

thot react with aldehydes during the thermosetfing thot react with aldehydes during the thermosetfing

process. Manufacturing improvements soon enabled process. Manufacturing improvements soon enabled

plastic laminate to resist plastic laminate to resist cigarettecigarette burns, and the  burns, and the

material became more attractive, colorful, and material became more attractive, colorful, and

durable, spurring its use by manufacturers of durable, spurring its use by manufacturers of

kitchen and dining furniture. kitchen and dining furniture.

Laminating Aluminum FoilLaminating Aluminum Foil

Laminating consists basically of Laminating consists basically of combining combining

a web or sheet of aluminum foil with one a web or sheet of aluminum foil with one

or more other materials, such as paper or more other materials, such as paper

and plastic films, using an adhesive, and plastic films, using an adhesive,

pressure, and usually heat for controlling pressure, and usually heat for controlling

adhesive viscosity, drying and/or thermo-adhesive viscosity, drying and/or thermo-

setting the bonding agent.setting the bonding agent.

Raw MaterialsRaw MaterialsDecorative plastic laminate sheeting is made of Decorative plastic laminate sheeting is made of resins that react with aldehydes during the resins that react with aldehydes during the thermosetting process. The resins are laminated thermosetting process. The resins are laminated onto layers of kraft paper topped with a onto layers of kraft paper topped with a decorative sheet. Kraft paper is the same brown decorative sheet. Kraft paper is the same brown paper used in grocery bags. The first plastic paper used in grocery bags. The first plastic laminates were made with phenolic resin, a laminates were made with phenolic resin, a polymer of formaldehyde and phenol. Phenolic polymer of formaldehyde and phenol. Phenolic resins produce only dark colors. a urea-based resins produce only dark colors. a urea-based resin called melamine was developed that resin called melamine was developed that produced a clear surface. In the modern produced a clear surface. In the modern manufacturing process, the top two layers of manufacturing process, the top two layers of paper are impregnated with melamine resin, paper are impregnated with melamine resin,

and and the lower layers use phenolic.the lower layers use phenolic.

The Manufacturing ProcessThe Manufacturing Process

Impregnating the paperImpregnating the paper1. The process begins by soaking strips of 1. The process begins by soaking strips of

paper in resin. Decorative plastic paper in resin. Decorative plastic laminates can be made in different laminates can be made in different grades or thicknesses, depending on its grades or thicknesses, depending on its intended use.intended use.

The kraft paper is run through a "bathtub" The kraft paper is run through a "bathtub" or vat containing phenolic resins. This is or vat containing phenolic resins. This is run through a vat of melamine resin. The run through a vat of melamine resin. The layer just beneath the top is the decorative layer just beneath the top is the decorative layer. layer.

DryingDrying

2. The resin-impregnated sheets are 2. The resin-impregnated sheets are then put into a drying chamber. Next, then put into a drying chamber. Next, they are cut and stacked in layers. The they are cut and stacked in layers. The clear layer and the decorative layer are clear layer and the decorative layer are on top of the kraft paper.on top of the kraft paper.

ThermosettingThermosetting 3. The layers of paper are then loaded onto 3. The layers of paper are then loaded onto

a flat-bed hydraulic press for final curing.a flat-bed hydraulic press for final curing.

The heat catalyzes a reaction in the resins. The heat catalyzes a reaction in the resins. The phenol (or melamine) and formaldehyde The phenol (or melamine) and formaldehyde molecules to each other in an alternating molecules to each other in an alternating chain fashion, releasing water molecules in chain fashion, releasing water molecules in the process. The resins flow together and the process. The resins flow together and then set. Thermosetting converts the paper then set. Thermosetting converts the paper sheets into one single, rigid laminated sheet. sheets into one single, rigid laminated sheet. This sheet is dry and insoluble, and it cannot This sheet is dry and insoluble, and it cannot be shaped or molded, even at high be shaped or molded, even at high temperatures. temperatures.

FinishingFinishing

4. The dry sheet is cut into the desired 4. The dry sheet is cut into the desired size and shape. It may also be size and shape. It may also be bonded to a building material such as bonded to a building material such as plywood, flake board, fiberboard, or plywood, flake board, fiberboard, or metal.metal.

Byproducts/WasteByproducts/WasteThe plastic laminate manufacturing The plastic laminate manufacturing process produces several byproducts, process produces several byproducts, some of which are considered hazardous. some of which are considered hazardous. Toxic emissions emanate from phenolic Toxic emissions emanate from phenolic resins during the laminating process, and resins during the laminating process, and acrylic resins and hardeners used in acrylic resins and hardeners used in applying plastic laminates to surfaces are applying plastic laminates to surfaces are also considered hazardous. Decorative also considered hazardous. Decorative plastic laminate itself is not considered a plastic laminate itself is not considered a "recyclable" plastic."recyclable" plastic.

Paper and laminate residue generated during Paper and laminate residue generated during

the manufacturing process are burned in power the manufacturing process are burned in power

boilers. Metal-based pigments used in boilers. Metal-based pigments used in

decorative papers also create a waste problem, decorative papers also create a waste problem,

as these can be hazardous. The leading as these can be hazardous. The leading

manufacturer of plastic laminate has for this manufacturer of plastic laminate has for this

reason reduced the use of such pigments, and reason reduced the use of such pigments, and

plans to totally eliminate the use of metal-based plans to totally eliminate the use of metal-based

pigments in the future. Although used laminate pigments in the future. Although used laminate

is not recyclable, some companies have is not recyclable, some companies have collated collated

old laminates into new sample sets suitable for old laminates into new sample sets suitable for

distribution.distribution.

ALL KIND OF PAPER ALL KIND OF PAPER &PLASTIC APPLICATION:&PLASTIC APPLICATION:

POLYCARBONATE FILMPOLYCARBONATE FILM

Application printing, insulantion, Application printing, insulantion, electro plate, forming grade etc. electro plate, forming grade etc.

PVC, HIPS, PP, PS, PE, PMMAPVC, HIPS, PP, PS, PE, PMMA

Application in printing & electronic Application in printing & electronic insulation.insulation.

DIFFUSION AND REFLECTOR FILMDIFFUSION AND REFLECTOR FILM

EL-GradeEL-Grade

Application in EL overlays and name Application in EL overlays and name plates. Auto glass file, solar cells and plates. Auto glass file, solar cells and opto electronics.opto electronics.

TOUCH PANEL GradeTOUCH PANEL Grade

Applicable in display/touch panel Applicable in display/touch panel display area, liquid crystal cell of display area, liquid crystal cell of LCD and TFT display.LCD and TFT display.

ELECTRO-PLATING MIRROR SHEETELECTRO-PLATING MIRROR SHEET

Applicable in convex mirror, display Applicable in convex mirror, display panel, toy product.panel, toy product.

POLYESTER FILMPOLYESTER FILM

Polyester film is used in a wide range of Polyester film is used in a wide range of electron: and electric insulation electron: and electric insulation applications, because of the applications, because of the outstanding dielectric strength and outstanding dielectric strength and superior mechanical property.superior mechanical property.

POLYIMIDE FILMPOLYIMIDE FILM

Polyimide film is widely used for Polyimide film is widely used for electrical and electronics appliances electrical and electronics appliances with properties of heat resistance with properties of heat resistance (almost no organic or inorganic (almost no organic or inorganic solvents except caustic alkali), solvents except caustic alkali), dielectric, flame retardant, physical, dielectric, flame retardant, physical, mechanical and compounded with mechanical and compounded with many materials performances.many materials performances.