Flat lamination of boards and panels is frequently used in the construction and furniture industry.
Panels made of a wide variety of materials are bonded with decors over the entire surface. The basic materials are wood-based materials (MDF and chipboard), as well as veneers, CPL, HPL, but also plastic sheets such as PVC or polypropylene.
These are optically refined in the panel lamination with decorative materials such as thermoplastic films, paper decorations but also veneers. The surface-laminated panels are used in a wide variety of areas, such as door panels, furniture elements, floors, ceiling panels, but also as kitchen fronts, wall panelling or material in caravan and ship building. Furniture designers and architects are constantly working on innovative trends and products, which has led to an endless range of decors, colours and surface solutions.
These often pose special challenges for the manufacturing companies. High gloss or super matt surfaces, for example, are very demanding to produce and require expert knowledge in terms of lamination and sheathing of panels and boards.
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The demands on the product are as diverse as the areas of application. The basic prerequisite for a high-quality product is always a flawless finish without surface defects such as wrinkles, inclusions or waves. On the other hand, the product should have the longest possible service life, which is particularly ensured by the durability of the bonding. TAKA has many years of experience in the field of profile and flat lamination and employs a team of specialists who are available to advise our customers on all questions and projects. In this way we ensure that, thanks to our adhesives, our customers are able to manufacture high-quality and competitive products that meet the highest demands. Our specially founded ACADEMY offers special training courses on the subject of flat lamination, aimed at machine operators as well as production managers.
In flat lamination and panel wrapping, hot melt adhesives are usually used to bond the decorative films over the entire surface. This is usually done on industrial panel laminating machines, which apply the adhesive to the decorative material either by means of a slot nozzle or by roller application to the panel to be laminated. Depending on the production process, different working parameters must be observed to achieve the best possible results. In general, when there are above-average demands on the quality of the bond, PUR hotmelt adhesives are used, as they have the highest resistance to heat, moisture and chemical substances of all hotmelt adhesives. In addition, reactive polyurethane hotmelt adhesives are free of formaldehyde, which is an important factor, especially in the furniture industry, as there are strict restrictions on the use and emissions of formaldehyde.
Roller application in flat lamination is still the most widespread application method. The PUR adhesive is melted in a melter or directly between the rollers and then applied to the panel using a rotating application roller. The decorative material is then glued to the panel either from a roll or as a piece using a pressure roller. Regarding the adhesive, parameters such as “open time” (working life), viscosity and, in particular, stability of the adhesive (pot-life) play a decisive role. The disadvantages of the roller application process are the imprecise adhesive application and the high cleaning costs of the system.
Slot nozzle application is still the most technically advanced solution for flat lamination. It is characterised by economical adhesive consumption and maximum precision in the adhesive pattern, which means that even demanding surfaces such as high-gloss and matt finishes can be produced in reliable processes. Similarly, slot die application offers maximum flexibility in the application width of the adhesive and enables the panel edges to be wrapped (postforming) in the same process step. At the same time, slot nozzles require little maintenance and are easy to clean, which saves a lot of time compared to roller application. The only limitation of this flat lamination process is the exclusive use of roll material as decorative material; individual sheets of veneer, for example, cannot be processed.
TAKA optimises its in-house production processes with efficiency but also sustainability in mind. PUR adhesives are manufactured on the most modern production facilities, which are powered by electricity from 100% renewable energy sources. We work with closed water systems so that no fresh or drinking water has to be fed in and rely on certified waste prevention and disposal solutions.
At the same time, TAKA has started to produce so-called “bio-based” products in its in-house production of polyesters, which are increasingly based on non-fossil raw materials but consist of organic, renewable raw materials. In this way, we are making an important contribution to reducing our carbon footprint, as well as reducing the CO2 emissions of our customers and the entire supply chain of the respective end product.
