Flame Lamination Machine Design and Gas Control
topic
Flame lamination machines pass polyurethane foam through an open gas flame of defined width and intensity that melts the foam surface to a tacky molten state within 0.1 to 0.3 seconds of flame contact before immediately bonding to the textile layer in a pressure nip, with gas type, burner design, flame-to-foam distance, and machine speed together controlling the melt depth of 0.1 to 0.5 millimetres that determines bond strength without excessive foam burn-off.
Role
Controls the foam surface melt depth that governs adhesive available for bonding and the resulting peel strength of the flame-laminated composite, with flame intensity and dwell time requiring careful optimisation at the critical balance between insufficient melt that produces weak bonds and excessive flame that burns through the foam or causes VOC release from foam pyrolysis that exceeds workplace air quality limits and environmental emission standards.