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01-11-2021

Variant for Flame Lamination of Polyurethane Foams

New Technology

Novel, emission reduced and efficient technology variant for flame lamination of polyurethane foams established within the research project “PU-Kasch”. Flame lamination is a process to manufacture decorative textile laminates consisting of a polymeric foam and a textile cover layer. However, the polyurethane foam-treatment with a gas flame and the associated gas combustion leads to emissions that need to be treated. This gave the aim of the project to develop an environmental-ly friendly, low-emission and economical process variant for the continuous produc-tion of textile laminates.

Development of a low-emission and economical process variant for the continuous production of textile laminates (© NMB)

Textile laminates are mainly used in the field of automotive interior trims on car seats and roof linings. During the production of such textile laminates by flame lamination, decorative textiles are bonded with a polyurethane foam by first flaming the surface of the foam layer immediately followed by a joining with the textile layer in a defined calender gap.

As part of the project “PU Kasch”, the project team, consisting of Hofer Textilveredelungs GmbH and the research institutes Neue Materialien Bayreuth GmbH and Hof University of Applied Sciences, developed an economical and low-emission process variant for a continuous production of textile laminates via flame lamination.

Textile Laminates of Satisfying Adhesion

By substituting inefficient conventional gas burners, it is possible to produce textile laminates of satisfying adhesion with significantly reduced emissions and lower gas consumption. Compared to a conventional burner the gas consumption was re-duced by about 40 %. Moreover, due to the optimized combustion also the emissions of total volatile organic compounds (VOC) could be reduced to about a quarter of the currently released VOCs. Since the trials have been carried out on an industrial scale plant, they are of great importance for series production.

Decorative textiles are bonded with a polyurethane foam by first flaming the surface of the foam layer immediately followed by a joining with the textile layer in a defined calender gap (© NMB)

As a further result, it was found that by a certain pretreatment of the textiles, the re-quired adhesion strength could be further exceeded at constant production speed. Thus, a higher production speed can be achieved while guaranteeing the required adhesive strength. In addition to the economic advantages, higher production speed also leads to reduced foam burn-off. This in turn lowers emissions and reduces the input of foam. The novel process variant contributes to establishing more efficient and environ-mentally friendly process chains for the production of future automobiles and com-mercial vehicles. This is not only a great advantage in terms of operating costs. Moreover, the low-emission process sustainably relieves environment.

Programme "New Materials”

The project "PU Kasch - Alternative Technologies for Lamination of Polyurethane Foams" has been carried out in the programme "New Materials” (project code NW-1710-0001). The project partners would like to thank the Bavarian State Ministry of Economic Affairs, Regional Development and Energy for funding.

Company profile

Neue Materialien Bayreuth GmbH

Gottlieb-Keim-Straße 60
DE 95448 Bayreuth
Tel.: 0921 50736-0

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