Chapter 13: Laminated Materials

Cobi Adrian

History

• Lamination is the technique of manufacturing a material in multiple layers, so that the composite material achieves improved strength, stability, sound insulation, and appearance.

• Laminate is a man made material that has been used in surfaces such as counters and back splashes since the early 1920’s.

• First introduced in the 1930’s, lamination became the primary choice for repairing and strengthening paper

• The first laminate flooring was invented in Sweden in 1977 by a company called Perstorp.

• In 1984 they began marketing the product in Europe under the name of “Pergo” and by 90’s had spread to the US.

• Glueless interlocking laminate flooring was invented by two separate companies at the same time in Europe during th years 1996 and 1997.

• Products like laminate stone, wood, leather, cork and metal would continue to evolve throughout the 2000’s.

Manufacturing

• In simplest manifestation of laminated materials, there will be a substrate and a facing material. • The substrate is selected for performance while the facing material is selected

for appearance.

• Laminate products will encounter substrates that are cellulosic products, like engineered wood sheets. In other instances they can be materials like porcelain, metal, plastic, paper, and glass. These substrate materials can also be found in unusual form applications like honeycomb paper and foamed metal.

• Cellulosic- besides plywood, particleboard, and medium density fiberboard, there is another material called high-density fiberboard or HDF. HDF is a common laminated material but is not commonly used under finishes.

• These materials are then attached to each other with an adhesive, like a glue, liquid concrete, contact cement. Some materials comes pre-glued.

• They are then coated or impregnated with resins or densifiers, (sealants)

Manufacturing

Laminated Object Manufacturing:

• Rapid prototyping system developed by Helisys Inc. • Cubic Technologies is now the successor organization

• Layers of adhesive-coated paper, plastic, wood, or metal laminated are successively glued together and cut to shape with a knife or laser cutter.

• Objected printing with this technique is done by machine through drilling and printing.

Processes are rapidly developing and new product combinations are being frequently introduced to solve design problems.

Laminated Object Manufacturing

The process is performed as follows:• Sheet is adhered to a substrate with a heated roller• Laser traces desired dimensions of prototype• Laser cross hatches non-part area to facilitate waste

removal• Platform with completed layer moves down out of the way• Fresh sheet of material is rolled in position• Platforms move up into position to receive the next layer• The process is then repeated

http://www.youtube.com/watch?v=IGpF1xtIYB4

http://www.youtube.com/watch?v=V5k08Vf7rF0

Construction Detail

Application

• Counter tops

• Flooring

• Wall Covering

• Ceiling Installations

• Built Ins

• Furniture

Concerns

• A common concern with engineered substrates is the presence of formaldehydes, which are common in a lot of glues and resins.

• If the material had been fireproofed with chemicals, toxins may still be present

• If not fire proofed flammability is often a concern because many plastics are highly flammable.

• Because the material isn’t one solid piece but rather a facing and a substrate the facing can be damaged and chipped, leaving the substrate visible.

Protection and Maintenance

• Even though the facing of the material isn’t solid all the way through it should be treated as. • For example: dimensional stone and wood should be

sealed, as should veneered stone and wood. • Regular maintenance or materials with natural facings

should equally be treated as solid materials.

• Methods of repairing these materials differ from solid materials and sometimes repairs cannot be made at all. Because the facing is often a thin layer, the material cannot be sanded or grinded for repair. It is best to order “attic stock” for your client to store in case of situations like these.

Sustainability

• Laminate materials are available with recycled material content either in the substrate or the finish face.

• Many laminate leather flooring is made from recycled leather laminated to hardboard that contain post-production waste wood.

• Because the product is easily damaged and cannot be repaired and re-used it often ends up in land fills.

• Just like many other products, laminate materials are often adhered using urea formaldehyde, and is sealed with acrylic.

• Overall the process of making laminate materials produce toxins that are released into the environment and air.

Installation

• When determining the best installation method for laminated materials you have to consider the material, particularly the one on the back of the assembly (the substrate).

• Whether the material will be affixed or adhered, mechanically, like fasteners and a cleat system, or by the use of adhesives.

• Laminate flooring often requires an underlayment.

• Stone Veneer Products is often installed using a cement mortar or mastic.

• Modular Systems and Custom Installations often come with specifications with specific means of installing the product, like hanging systems, bolts, and screws.

Installation

Installation

Installation

Cost

• Cost of a laminate material and the installation of it differs from material to material. Factors that effect the cost include quantity, type of material, and whether it is custom work or not.

• In general laminate materials are cheaper than buying the real thing. For example laminate cheery wood flooring is often cheaper then real cheery wood flooring.

• Switching materials to laminate materials is one way we as designers can put a project back on budget, without changing the design of a space in a dramatic way

Flooring Cost Break Down

Counter Top Cost Break Down

Pop Quiz

1. In it simplest, laminate materials are made out of a blank + blank?

Facing and Substrate

Pop Quiz

2. Give an example of a cellulosic:

Plywood, particleboard, MDF, HDF

Pop Quiz

3. The substrate and facing material are attached together using what substance?

Glue, Liquid Concrete, Contact Cement

Pop Quiz

4. In the final phase of manufacturing, the laminate material is coated or impregnated with?

Resins, Densifiers, Sealants

Pop Quiz

5. List three types of applications for a laminate material:

Counter Top, Furniture, Flooring, Wall Covering, Ceiling Installation, Built Ins

Pop Quiz

6. List three types of Laminate Materials:

Wood, Metal, Plastic, Stone, Textile, Cork, Leather