Foam Light is our top selling product because of its tremendous advantages over solid wood. Foam Light can provide up to an 85% weight reduction compared to plywood, particle board, and medium density fiberboard (MDF). It is composed of two layers. The inner layer is composed of Extruded Polystyrene Foam (EPS), which provides the highest level of rigidity and moisture resistance with the lightest possible weight, the outer layer is top quality High Density Fiberboard (HDF).

Facing materials can easily be applied Foam Light such as veneers, laminates, and decorative metals. Edging can also be finished in a variety of options. Finally, the rigid outer layer face allows a wide range of methods for attachment. For all of these reasons, Foam Light is perfect for applications such as ceiling beams, suspended panels, architectural panels, store fixtures, shelving, and signage.

Advantages of Polyurethane (PUR) Lamination

One of the key differences between the Thinklightweight family of products and our competition is that we use Polyurethane (PUR) Lamination process as opposed to “White Glue” lamination process. This is also known as Polyethenyl (PVA) lamination process. In the white glue lamination process, white or water based adhesive is applied at room temperature to core wood material. The core material is then positioned typically into a cold press and it might be passed through a heated pinch roller. However, the activation of the adhesive is accomplished by that moisture being absorbed into the material. Unfortunately, this causes the moisture rate of the wood to be increased and that creates instability. Because of different atmospheres and humidity levels, the moisture within the wood will be released. As a result, the panel warps.

We have determined that the best manufacturing method to provide you with a stable, consistent product is using a Polyurethane (PUR) Lamination process. In this process, PUR adhesive is heated and passed through pressure lines where the glue spreader provides the precise amount adhesive needed on both sides of the core material before it is passed through our state of the art Fixed Opening Press. Ninety seconds after it has passed through the press, we have achieved an 85% green strength (The term “green strength” is used to describe a finished product that has not yet cured completely or been sintered or hardened) with no moisture.

White Glue Lamination Process

  1. PVA adhesive is applied at room temperature to core material.
  2. Face material is applied to both sides of core material.
  3. Assembly proceeds through cold press.
  4. Glue set is accomplished by through panel absorption.

RESULT: Moisture content of panel has been artificially increased and warps the panel as released over time.

Polyurethane Resin Lamination Process

  1. PUR Adhesive is heated, pressurized and is applied by the double-sided applicator on to the core material.
  2. Face material is applied to both sided of core material.
  3. Assembly proceeds through ten station fixed opening roller press.
  4. Glue is activated by heat and humidity and initial green strength of adhesive is achieved in 90 seconds.

RESULT: Moisture content of the panel has not been effected nor has panel stability form the lamination process.

The white glue lamination process is an old-fashioned methodology. Our PUR lamination technology is state of the art and the reason why we are able to eliminate the moisture content in our product and its associated warping.