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888.679.9825
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888.679.9825

BC Adhesives - Sponge Assembly

BC Adhesives is a trusted provider of high-quality sponge / foam lamination adhesives. With years of experience in the industry, we understand the importance of a secure and reliable bond between your different substrate layers. Understanding the different adhesive options and equipment necessary can help you choose the right solution.

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Manufacturing process for sponge lamination

The manufacturing process of laminating kitchen sponges with adhesive typically involves several steps:

Material Preparation:

  • The team gathers and prepares raw materials, including sponge material and adhesive, for the manufacturing process.

Cutting and Shaping:

  • Sponge material is cut into shapes and sizes based on the desired final product.

Adhesive Application:

  • Specially formulated adhesive coats the sponge surface, ensuring even distribution, typically achieved with a roll coater. A wide range of hot melt and liquid polyurethane (PUR) adhesives suits various application requirements.

Layering:

  • The process stacks multiple layers of sponge material, using adhesive as the bonding agent between the layers.

Pressing and Bonding:

  • A pressing mechanism compresses the layered sponge materials. This pressure helps to bond the layers together securely, allowing the adhesive to create a strong and durable connection.

Curing or Drying:

  • The bonded sponge layers go through a curing or drying process. This step is essential to allow the adhesive to set and achieve optimal strength. We have products that are faster or slower depending on your requirements.

Quality Control:

  • The laminated sponges undergo quality control checks to ensure that the adhesive has created a solid bond and that the overall product meets specified standards.

Trimming and Finishing:

  • The process trims excess material, shapes the sponges to their final form, and addresses any imperfections.

Packaging:

  • The finished kitchen sponges are packaged and prepared for distribution.

Throughout the entire process, manufacturers may implement quality assurance measures to ensure the consistency and reliability of the laminated kitchen sponges. The choice of adhesive and the precision of application are critical factors in producing high-quality sponges that meet performance expectations. Trust the team at BC Adhesives to help choose the right product for your application and substrates.

Common equipment used for sponge lamination

The lamination of foam layers in the sponge assembly process involves specific equipment designed to ensure proper bonding and layering. Commonly used key equipment includes:

Laminating Machine:

  • A specialized machine handles the lamination process. It typically consists of rollers that apply adhesive to the layers of foam prior to the bonding process.

Adhesive Applicator:

  • An adhesive applicator connects to the lamination machine, evenly applying adhesive to the foam layers. This can include spray systems, rollers, or other applicators depending on the adhesive type and manufacturing requirements.

Conveyor System:

  • Conveyors transport sponge foam layers through the stages of the lamination process. They ensure a smooth and controlled movement of materials, allowing for precise adhesive bonding.

Pressing Mechanism:

  • Hydraulic or pneumatic presses apply the pressure needed to bond the foam layers together. The pressing mechanism can be adjustable to accommodate different materials and thicknesses.

Drying or Curing System:

  • Equipment for drying or curing the adhesive after lamination. This may include ovens, infrared systems, or other drying methods, depending on the type of adhesive used.

Cutting and Trimming Tools:

  • Cutting and trimming tools shape the laminated foam into its final form. This can include die-cutting machines, knives, or other cutting tools.

Quality Control Devices:

  • Sensors and inspection systems monitor the lamination process to ensure the quality of the bonded foam layers. These devices may detect irregularities or variations in the lamination.

Temperature and Humidity Controls:

  • Some manufacturing processes require specific temperature and humidity conditions for optimal adhesive performance. Equipment such as climate control systems should be used to maintain the ideal environment.

Roller Systems:

  • Rollers are commonly used in the lamination process to ensure even pressure distribution across the foam layers. They help in achieving uniform bonding.

Material Handling Systems:

  • Equipment for handling and feeding raw materials into the lamination process efficiently.

The combination of these equipment types allows manufacturers to control the lamination process effectively, ensuring their foam layers are securely bonded with adhesive, resulting in high-quality laminated sponges. Struggling to find the right adhesive for your needs? Contact info@bcadhesives.com to discuss your sponge / foam lamination project.

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Contact us today to learn more about the various adhesives you should be implementing into your sponge manufacturing process! With more than two decades of experience, our trusted team can therefore help you optimize your workflow and work towards a healthier planet.

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Adhesives used for sponge lamination

We have many different laminating glues that have been proven and used in the sponge lamination process for many years.

Some of our glues include:

  • Liquid polyurethanes with different open times and cure times to meet your processing needs.
  • Hot melt polyurethanes with different open times and cure times to meet your processing needs.

As you can see, adhesives are a crucial in the sponge assembly process.

Trust our experts to help you identify the ideal adhesive solutions to meet your specific requirements and achieve success in your projects.

Contact an expert at BC Adhesives

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“BC Adhesives is the best full service supplier we have worked with as they are both experts on the equipment and adhesive sides of the business. When our company was struggling to find the perfect adhesives for our applications, BC’s sales representative was on it. She provided alternate products and testing until we found the right solution. In addition to just providing us adhesive, they are always willing to come in to look at our equipment, and train our staff to better develop their skill sets. This was a win not just for us but for our customers as well. I know we can count on them 24/7 as they go above and beyond just selling adhesives.”
“BC’s customer service is second to none! They’re always there whenever I have questions or concerns. Any issues that arise are dealt with immediately and thoroughly. They are a first class organization and a true pleasure to work with.”
“A service and expertise partnership is what we have found in BC Adhesives. For the past 16 years, we have counted on BC’s guidance regarding adhesives. We have many different glue applications at our company and they make sure we are running the best products for each operation. We could not be more thankful for the support of the whole team at BC Adhesives.”
“Our company has worked with BC Adhesives from the installation of our first perfect binder – 20 years ago. Ed and his team came in and trained all of our operators and checked in regularly with them to ensure they understood how to use the pre-melters, how to do proper spine prep and how to test that the books have the proper amount of glue to make a long standing backbone. The team at BC Adhesives is not just a vendor – they are the true definition of a partner. We appreciate their passion for their business, and for ours!”
BC Adhesives
Midwestern Values. World Class Brands.
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Franklin, WI 53132
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