Home > Lamination > Double Belt Press Lamination: Frequently Asked Questions And More

belt lamination machineCurious about double belt press lamination? It’s easy to understand why. When you explore lamination, composites, and how to produce them, this process immediately comes to the surface. But while it’s a great option for many lamination projects, it’s not right for everyone. Conversion Technologies International is here to define what makes this process so valuable, and when you should choose it.

What is double belt press lamination?

Double belt press lamination is a form of manufacturing. Reliant on continuous motion, it uses synchronized upper and lower conveyor belt systems to fuse substrates together. Relying on high pressure and varying temperatures, these coating & converting technologies create layered, laminated materials. Essentially, it’s a form of thermal lamination, taking advantage of thermoplastic bonding to create the desired product.

How does a double belt press work?

A double belt laminator works through several different steps, working through heat and pressure lamination. Every machine has an adjustable gap between two moving conveyor belts. After selecting a material, we continuously feed it through that gap. At that point, the material works into what we call the “heating zone”. The heat exposure melts the material, making it more malleable and able to bond. It’s a form of activation, which makes it crucial to the to the overall adhesive lamination process.

Next is the pressure zone—the second part of that pressurized lamination we mentioned earlier. This really sets the bond between the two materials and makes the layers as smooth as possible. It’s easy for air bubbles to form and create structural weaknesses without this step. The pressure zone keeps that from happening, ensuring the best possible results.

The cooling zone chills the adhesive coating, hardening the layers and finishing the sealing process. This kind of belt lamination finishes the laminated materials, ultimately giving you a product that is resistant to damage, aesthetically appealing, and practically functional.

What materials can we process with a double belt press?

If a product requires thermal lamination, we can probably use a double belt laminator to process it. But a few types stand out in particular, including:

  • Granulates and powders. These products come in the form of loose particles, though they’re actually made up of polymers. We consolidate them into solid sheets, producing multilayer materials.
  • Cores and structural layers. Think of PP honeycomb structures, PET foam, and PP foam here. These products allow us to create layers that resemble a “sandwich” format.
  • Functional surface layers. In this case, we use a continuous belt press to create anti-skid coatings, metal foils, decorative films, and specialized laminates.
  • Fibrous reinforcements. These materials include glass fiber and carbon fiber, as well as natural fibers, unidirectional tapes, woven fiber mats, and woven fabrics.
  • Thermoplastics and thermosets. Here, we work with sheets, films, and matrices made up of PP, PET, and other types of polymers.
  • Special composites. This category covers everything from fireproof composites to artificial stone. You may also find flexible substrates under the special composites “umbrella”.

If you find yourself working with these types of materials, double belt press lamination could be the right option. We always recommend consulting with an experienced third-party manufacturer before making a final decision.

Frequently Asked Questions

These aren’t the only questions we cover when it comes to continuous lamination. Let’s dive into a few others.

What is the difference between double belt lamination and hot roll lamination?

Both double belt press lamination and hot roll lamination serve as forms of roll-to-roll processing. However, they come with a few key differences. Hot roll lamination moves the material through at least two heated rollers, sometimes referred to as “nip rollers”. This web converting process allows you to move more quickly. It works well with thinner materials, and ensures affordable efficiency with a faster setup.

Essentially, hot roll lamination lacks the heating and cooling variation of double belt press lamination. Nor does it use pressure to the extent that a double belt press laminator would.

When should a manufacturer use continuous belt lamination?

A few different scenarios point toward the use of continuous belt lamination. Consider the volume of the order as well as the need for speed. If you’re looking for continuous production, delivering a large volume of product in a regular, predictable manner, continuous belt lamination could be for you.

Additionally, if you’re working with technical textiles, composite materials, or foam sandwiches, continuous belt lamination is usually a natural choice. Add these factors together, and you really don’t have to think much longer. Bring up continuous belt lamination with your potential third party. You’ll get the most consistent product possible.

How do temperature, pressure, and dwell time affect laminate quality?

Above, we alluded to the need for pressure when working with continuous lamination. The pressure itself helps smooth out any pockets of air and prevents structural weaknesses. Similarly, the product cannot properly “melt”—becoming flexible—without the right amount of heat. Nor can it harden as it should without the right cooling effect.

Dwell time, on the other hand, acts as a time period for completion. If the dwell time is too short, the heat can’t work through multiple layers. This creates a defective product. If the materials layer under high heat for too long, however, you’re losing time and energy. Additionally, the heat can degrade the materials and result in resin leakage. You have to balance the timing, the temperatures, and the pressure to create the right product.

What industries use double belt press lamination?

The industries that use double belt press lamination include:

  • Aerospace
  • Automotive
  • Construction
  • Technical textiles
  • Commercial transportation
  • Flooring
  • Sporting goods
  • And more!

If you have more questions, that’s no problem! Call CTI at 419-924-5566 or contact us here.