Converting

As a fully integrated materials supplier, we have the engineering know-how and converting technologies to take your project from concept to a high quality foam solution. Rubberlite offers skiving to thickness, slitting to width, and pressure-sensitive adhesive laminations to meet or exceed your individual needs.

Skiving

Rubberlite’s skiving technologies sets the industry standard for splitting expanded rubber, plastics and internally produced polyurethane foams with unprecedented gauge control and tight tolerance capability. Utilizing Statistical Process Control methods with the most advanced converting machinery, our skilled operators convert a diverse line of open and closed-cell foams into accurately skived materials to your specification.

Buffing

As an extension to Rubberlite’s expertise for converting tight thickness-specification materials, our buffing process utilizes an industrial abrasive cylinder to produce a clean and accurate surface profile. When dimensional tolerances are critical for precision parts, this value-added service affords repeatable and reliable conformance to your specification.

PSA Lamination

Rubberlite’s multiple wide-format lamination processes apply liner-backed PSAs to our large selection of cellular materials in an array of widths and thicknesses. To ensure optimal adhesion and quality, a variety of laminating adhesive types and grades are selected from the leading suppliers of rubber and acrylic-based PSA products including:

  • CCT
  • Adchem
  • Avery Dennison
  • 3M

Slitting

Rubberlite offers accurate slitting and stripping to width for a variety of materials and thicknesses. To accommodate longer lengths for automated fabrication or manufacturing lines, Rubberlite has the capability to strip materials on continuous reels with custom labeling and packaging services as well.

Custom Foam Manufacturing

Our manufacturing facility for custom-engineered foam solutions is staffed by our own development specialists.

Custom Solutions

Custom Solutions from Rubberlite

Rubberlite offers a unique portfolio of microcellular polyurethane foams to meet demanding requirements across a diverse range of applications. Under the trademarks of HyPUR-cel® high resilient foams and Viscocel® viscoelastic foams, Rubberlite has engineered a broad range polyurethane products unconstrained by systems house chemistries and free of external blowing agents. This makes for a versatile and environmentally friendly process poised to meet industry demands with the broadest ranges of density, firmness, and thickness in the microcellular industry.

In addition to an extensive list of standard products, Rubberlite can custom engineer foams to specific physical property and performance targets. By developing and maintaining ownership of the process and composition technologies intrinsic to HyPUR-cel® and Viscocel®, new products can be readily developed from the formularies that make up the portfolio of S-Series, T-Series, I-Series, and V-Series.

Combined with substantial in-house value-add capabilities, Rubberlite’s polyurethane foam technology offers a comprehensive solution based approach to product development and design.

In addition to custom colors and physical properties, a number of highly functional additives can be incorporated for specific performance requirements. These include:

Function Nomenclature Function
Anti-microbial additives AM Bacterial and fungal control within the matrix of the foam
UV absorbers and stabilizers UV Prevents accelerated yellowing and degradation caused by UV Light
Colorfast black pigment CB Typically used in high UV exposure applications to maximize color fastness
Dispersed micronized rubber GT® Commonly used to incorporate recycle content

Further expanding product differentiation and design, Rubberlite has developed extensive capabilities in functional coatings for foams and textiles. With state of the art process equipment, formulation and application expertise has been developed to not only compliment the performance benefits of HyPUR-cel® and Viscocel®, but diversify into sophisticated textile surface modifiers and emulsion-based mechanically frothed thin layer foams.

With the implementation of new value-add propositions in coatings and laminations, combined with the mature and well-known foam technologies, Rubberlite is well positioned to provide customer solutions in foam design, technical composites, and novel textile coatings applications.

Foam Finishing Technology

Bridging advanced coating technologies and polymer formulation solutions results in unique functional composites for market-specific applications.

Foam Finishing Technology is comprised of several application processes that impact the look, feel, and performance of a coated technical composite. At Rubberlite, we incorporate the best-in-class processes such as paste coating, stable-to-instable foam coating and finishing, as well as precision-controlled screen printing to deliver a platform of application techniques for ultimate design flexibility.

Through collaboration with our customers and development partners, our R&D team selects the best combination of polymers, additives, substrate materials, and coating processes that contributes to the most effective solution for a given market application.

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