Flame Laminator #1 was in 10 Mill building on the second floor. The laminator encapsulated a nylon knitted scrim between two thin layers of polyurethane foam to give it tensile strength.
The lamination applied extreme heat to the surface of the top foam as it passed by the flame burner to make the surface of top foam tacky, just before advancing and joining the scrim and bottom foam between two steel chilled rolls (also called nip rolls). The nip rolls pressed the three layers to bond, or laminate, them together.
After passing through the nip rolls the laminated foam and scrim was called substrate, and advanced to the cutters to be trimmed at the desired length, then rolled into 400 yard rolls ,and were sent to the ranges.
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