LAMINATESSUBMITTED BY:SAMRIDHI GUPTAJAGMIT SINGH HARSIMRANJEET KAUR

SUBMITTED TO:AR. AAKRITI DHIMAN

Lamination is the technique of manufacturing a material in multiple layers, so that the composite material achieves improved strength, stability, sound insulation, appearance or other properties from the use of differing materials. A laminate is a permanently assembled object by heat, pressure, welding, or adhesives

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

.

MATERIALS

Vehicle windshields are commonly made by laminating a tough plastic film between two layers of glass. This is to prevent shards of glass detaching from the windshield in case it breaks. Plywood is a common example of a laminate using the same material in each layer. Glued and laminated dimensioned timber is used in the construction industry to make wooden beams, Glulam, with sizes larger and stronger than can be obtained from single pieces of wood. Another reason to laminate wooden strips into beams is quality control, as with this method each and every strip can be inspected before it becomes part of a highly stressed component

DECORATIVE LAMINATE

Decorative laminates are laminated products primarily used as furniture surface materials or wall paneling. It can be manufactured as either high- or low-pressure laminate, with the two processes not much different from each other except for the pressure applied in the pressing process.

It is said that the first decorative High Pressure Laminate was produced by Marc-Anton André, who is the sixth generation of Johann Ludwig André, in 1959.

According to McGraw-Hill Dictionary of Architecture & Construction, high-pressure laminates consists of laminates "molded and cured at pressures not lower than 1,000 lb per sq in. (70 kg per sq cm) and more commonly in the range of 1,200 to 2,000 lb per sq in. (84 to 140 kg per sq cm).

HIGH PRESSURE LAMINATES

LOW PRESSURE LAMINATES

Low Pressure laminate is defined as "a plastic laminate molded and cured at pressures in general of 400 pounds per square inch (approximately 27 atmospheres or 2.8 x 106 pascals).

QUALITY STANDARDSThere are various industrial standards specifically applied for high-pressure decorative laminates:

European Standard EN438The European Standard EN438 is one of the standards that most decorative laminates manufacturers selling to worldwide market (such as Abet Laminati, Dekodur Laminating Technologie, Violam, Formica, Maica, Wilsonart, Greenlam) adhere to. The specific code is EN438, entitled: Decorative high-pressure laminates (HPL) sheets based on thermosetting resins, specifications. It replaces the BS3794 standard.

The specific part of EN438 which applies to high-pressure laminates is Part 3. The full title to this standard is: High-pressure decorative laminates (HPL) Sheets based on thermosetting resins (Usually called laminates) Part 3: Classification and specifications for laminates less than 2 mm thick intended for bonding to supporting substrates. In total there are 9 parts to the EN438.

ANTIBACTERIAL

Antibacterial properties are important for decorative laminates because these laminates are used as kitchen tops and counter tops, cabinets and table tops that may be in constant contact with food materials and younger children. Antibacterial properties are there to ensure that bacterial growth is minimal.

One of the standards for Anti-Bacterial is the ISO 22196:2007, which is based on the Japanese Industrial Standards (JIS), code Z2801. This is one of the standards most often referred to in the industry with regards to tests on microbial activities (specifically bacteria) and in the JIS Z2801, two bacteria species are used as a standard, namely E. Coli and Staphylococcus aureus. However, some companies may have the initiative to test more than just these two bacteria and may also replace Staphylococcus aureus with MRSA, the methicillin-resistant version of the same bacteria.

Again, different countries may choose to specify different types of microbes for testing especially if they identified some bacteria groups which are more intimidating in their countries due to specific reasons.

A common anti-fungi standard is the ASTM G21-09. Not all manufacturers will take the initiatives for product R&D for anti-Fungi attributes. Manufacturers like Maica Laminates send their products for laboratory tests for certification following the ASTM G21-09 standard,[6] while Formica (South America) partners with Microban Protection,which is a company manufacturing additives, including the anti-bacterial additives.

ANTI FUNGI

There are many different standards with regards to fire-resistant and flame-retardant properties of high-pressure decorative laminates. While different countries may have different standards for the building industry to adhere to, most countries may agree on some of the more common standards being used in the industry. Very often, just like other standards applicable to the industry, the tests may be European Standards with their equivalent in the US Standards.

Fire-resistant and flame-retardant

For example, many Commonwealth countries may be comfortable with the British Standards 476 especially Parts 6 and 7, while there will still be US Standard equivalence in the ASTM.

The list of tests applicable to decorative laminates will never be exhaustive. As the technology improves, there will be many more tests to ensure the safety of the products upon use by the end consumer, for example perhaps the tests on transfer of surface substance to food materials if prepared on the decorative laminates as a kitchen surface. The core tests will then also branch out based on the specific requirements and standards adopted by different countries.

OTHERS

Two of the internationally acknowledged "Green" certificates for decorative laminates are MAS Certified Green and GREENGUARD. The MAS Certified Green and GREENGUARD marks are to certify that the products have low chemical emissions. Chemicals tested include VOCs, formaldehyde and other harmful particles. The tests are based on single occupancy room with outdoor ventilation following the ANSI/ASHRAE Standard 62.1-2007, Ventilation for Acceptable Indoor Air Quality. GREENGUARD especially, has two

GREEN CERTIFICATES

There are also many other "Green" certifications, some which are requirements by the authorities before the product can be used as building materials. These include the Singapore Green Label which is recognised by the Global Ecolabelling Network (GEN) and all its member countries.

main consideration, GREENGUARD and GREENGUARD GOLD. The GREENGUARD n GOLD was previously known as the GREENGUARD Children and Schools Certified, signifying its relevance of very low allowable chemical emissions levels to ensure the safety of young children and school environment.

APPLICATIONS

Decorative high-pressure laminates are usually used for furniture tops especially on flat surfaces, including cabinets and tables. Decorative compact laminates are sometimes constructed as toilet cubicle systems, laboratory tables and kitchen tops. Some new usage models include wall panels with conceptual designs and custom prints.

COMPETITION

The popularity of large format printing using inkjet printers have given a cheaper alternative to decorative laminates, minus the quality. For most uninformed consumers, the large format printing are similar to laminates, and seem to offer more variety of designs and applications. For example, large format prints can be printed on wall stickers, and then installed on walls. Unlike decorative laminates, there are no special adhesive to be used, and the price may sometimes seem so much cheaper comparatively.However, there are health considerations for large format prints because of the solvent inks used, especially with their relatively high concentrations of VOCs

Here are a few unconventional decorating ideas you can try at home with laminate sheets:

Choose a pattern that looks like stone for a “natural” table runner. It looks great underneath potted plants and other earthen displays.Line the inside back of a bookcase to make an interesting backdrop for books and collectibles.Apply laminate to a sheet of particleboard to create a custom headboard.Resurface a coffee or side table for enhanced eye appeal.Use as a photo backdrop for objects, pets or children.Resurface the wooden base of a bar. For an industrial chic look, try decorative metals.

Resurface a kid’s desk or art table For a place where water spills and crayon smudges are inevitable, laminate is the perfect, easy-to-maintain option.Apply it to stair risers to add an unexpected pop of color or pattern.Frame various-sized pieces, treating them as art; mix and match similar or varied patterns. Stone looks, such as 3474 Petrified Wood in the laminate line 180fx® by Formica Group, or graphic patterns, such as the Geo and Dogbone Collections and 6942 Charcoal Boomerang (pictured below) show well.

Resurface a worn wood breakfast tray to give it a new look. Try a woodgrain so that it still looks like wood (such as 204 Butcherblock Maple), or go for a bolder graphic or solid color laminate.

MANUFACTURING

Raw MaterialsDecorative plastic laminate sheeting is made of resins that react with aldehydes during the thermosetting process. The resins are laminated onto layers of kraft paper topped with a decorative sheet. Kraft paper is the same brown paper used in grocery bags. The first plastic laminates were made with phenolic resin, a polymer of formaldehyde and phenol. Phenolic resins produce only dark colors. In the 1930s, a urea-based resin called melamine was developed that produced a clear surface. In the modern manufacturing process, the top two layers of paper are impregnated with melamine resin, and the lower layers use phenolic.

MANUFACTURING PROCESS

Impregnating the paper1 The process begins by soaking strips of paper in resin. Decorative plastic laminates can be made in different grades or thicknesses, depending on its intended use. There may be from 7-18 layers of paper combined into the final sheet. The bottom layers are kraft paper. The paper comes in ribbons of different widths, commonly of three, four, or five feet. The kraft paper is run through a "bath tub" or vat containing phenolic resins. The paper for the top layer of the sheet is translucent. This is run through a vat of melamine resin.

The layer just beneath the top is the decorative layer. This is a sheet of paper printed with the color or design that will show through the clear top layer for the desired surface pattern. This sheet is also run through a melamine vat.

Drying2 The resin-impregnated sheets are then put into a drying chamber. Next, they are cut and stacked in layers. The clear layer and the decorative layer are on top of the kraft paper.Thermosetting3 The layers of paper are then loaded onto a flat-bed hydraulic press for final curing. The press compresses the sandwich of resin-soaked paper at 1,400 psi, while heating it to a high temperature. The heat catalyzes a reaction in the resins.

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

Finishing

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

The plastic laminate manufacturing process produces several by products, some of which are considered hazardous. Toxic emissions emanate from phenolic resins during the laminating process, and acrylic resins and hardeners used in applying plastic laminates to surfaces are also considered hazardous. Decorative plastic laminate itself is not considered a "recyclable" plastic. However, at least one major manufacturer has taken steps to reduce harmful waste and emissions.

BY PRODUCTS/WASTE

By switching from solvent based to water-based phenolic resins, the amount of toxins released during lamination can be reduced. Recent changes in the composition of melamine have also virtually eliminated alcohol emissions from this type of resin as well. Control devices such as so-called packed column scrubbers also reduce particulate emissions into the air.

Paper and laminate residue generated during the manufacturing process are burned in power boilers. This reduces the amount of waste sent to landfills. Metal-based pigments used in decorative papers also create a waste problem, as these can be hazardous. The leading manufacturer of plastic laminate has for this reason reduced the use of such pigments, and plans to totally eliminate the use of metal-based pigments in the future. Although used laminate is not recyclable, some companies have collated old laminates into new sample sets suitable for distribution.

Sunmica and other brands of Laminates in India usually have a thickness that ranges from 0.6 mm to 1.5 mm. The thicker self-supporting Compact laminates on the other hand have a thickness ranging from 3 mm to 30 mm

THICKNESS

The most standard size of laminate sheets produced by most of the laminate companies in India is 8'x 4'(8 feet by 4 feet). Some laminate manufacturers also make some laminate sheets in special sizes such as 3 feet x 7 feet, or 5 feet by 12 feet, but the standard and common size is 8'x 4'.

The prices of the laminates are specified by the plywood and laminate retailers in India in terms of cost (in Rs.) per sheet of laminate. On the contrary plywood rates are usually specified in terms of cost (Rs.) per square foot.

PRICES

THANK YOU