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Technical Composite Solutions

At Rubberlite, we integrate our technologies and expertise to design technical composite solutions that couple the best materials with innovative functionality. Technical composite solutions refer to a broad class of multi-layer products that are designed and engineered to meet stringent requirements for an array of markets and end uses. With an extensive background in material science, combined with our advanced lamination and coating technologies, Rubberlite creates high performing, specialty material composites for demanding applications. 

Laminations

Rubberlite’s laminating expertise provides the capability to laminate most any cellular foam with a wide variety of substrates including fabrics and films. Additionally, we can laminate fabric to fabric or foam to foam for dual function or dual density applications. Our lamination systems provide a nearly endless variety of combinations with incredible performance standards.

Our lamination composite products offer:

  • Lamination of stretch and non-stretch fabrics
  • Lamination of films, nonwovens & vinyls
  • Foam to foam (dual density)
  • Fabric to fabric (dual function)
  • Continuous composite rolls up to 60” wide
  • Solvent-free adhesive packages: PUR, PSA and water-based
  • Excellent bonds
  • Wide variety of stock fabrics

Rubberlite’s proprietary systems and expertise in bonding solutions afford our customers a single source for design, development and supply of high performing laminated composite materials. Our lamination capabilities maximize efficiency for our clients, providing unmatched quality, low minimums and quick delivery.

Unique to Rubberlite is our ability to recommend and provide access to our vast inventory of elastomeric compounds, plastic foams and wide selection of HyPUR-cel®. This vertically-integrated level of service has earned Rubberlite the reputation as a market leader for manufacturing laminated composite solutions.

A partial listing of applications include:

  • Orthopedic soft goods
  • Medical and health equipment
  • Automotive
  • Industrial belting
  • Equestrian
  • Shoe insoles
  • Outdoor equipment
  • Orthotics
  • Ergonomic/safety
  • Sporting goods
  • Computer and technology accessories

Functional Coatings

Coating Solutions for High Performance Composites

As a manufacturer of high performance technical composites, Rubberlite offers polymer coating solutions found in a variety of markets and end-uses. Our coating technologies consist of combining the benefits of function-specific foams and textiles with advanced polymer formulations that work together to create unique end products. Enhancing mechanical properties while achieving desirable look and feel characteristics is the primary focus of these customer-driven products. 

Functional Polymer Coatings

Functional coatings are engineered for a broad range of physical properties and surface features. All are aqueous-based formulations that are eco-friendly and scalable with a variety of additives, modifiers and fillers that result in enhanced functionality to meet demanding design requirements.

Our polymer coatings are used to develop new products or complement existing materials for improving several functional and aesthetic properties, such as variable hand, durability, water repellency, breathability, flame retardancy, anti-microbial protection, slip resistance, elasticity, as well as tinted surface textures and designs.

From simple to complex, design engineers have relied on Rubberlite to provide technical composites for enhancing the performance and visual appeal of materials in the sports/outdoor apparel, footwear, medical soft goods, industrial, automotive, and building and construction markets.

Typical Coating Applications and Benefits

  • Stable foam coatings – for an enhanced soft touch, conformance and cushioning
  • Durability coatings – for extending end product life/use
  • Flame retardant/anti-microbial coatings – for improving safety and protection
  • Anti-slip coatings – for controlling coefficient of friction and resisting migration
  • Nonstick coatings – for resisting adhesive bonding or blocking
  • Raised print – for increasing airflow, adding texture and design aesthetics

SUR-fex®

SUR-fex® Coated Composites are custom engineered solutions – bridging performance with aesthetics in the design of technical composites for demanding applications.

SUR-fex® coated composites features and advantages:

  • Custom formulations to enhance performance with a broad range of functional and aesthetic properties
  • Aqueous-based chemistries; compatible with a variety of substrates for creating high performing multi-layer composites
  • Multiple coating, printing and finishing technologies for exceptional design flexibility
  • Decorative print designs, 3D structures, surface textures and color effects

NS100

NS100 (non skid) reduces the slickness of a surface while providing additional space between adjoining smooth or flat surfaces. This durable water-based formulation can be applied as a full-coverage functional coating or in a design/pattern that further enhances the overall attributes of the substrate.

NS100 can be directly cast onto a wide range of flexible substrates, up to a thickness of 0.020” in continuous roll form. The improved coefficient of friction enables a more safe and secure end use application while maintaining flexibility and air permeability. NS100 satisfies the AATCC 61 requirements for 2A wash testing, and can be easily maintained to ensure cleanliness.

Download the Technical Sheet for NS100 

Download the Typical Property Sheet for NS100

SC100

SC100 (surface coat) modifies the surface characteristics of a substrate. Applied in full coverage, this water-based, latex-free formulation mimics the outer skin inherent on some foam materials. SC100 does not occlude moisture vapor transfer, allowing continued breathability of the base substrate. This reduces heat build-up and moisture which ensures overall comfort. 

SC100 can be directly cast on a wide range of HyPUR-cel® polyurethane foam in continuous roll-to-roll form at various widths. To ensure cleanliness, SC100 satisfies the AATCC 61 requirements for 2A wash testing. The SC100 coating allows the substrate breathability along with excellent durability, enhanced strength, improved elasticity and will benefit many performance applications. 

Download the Technical Sheet for SC100

Download the Typical Property Sheet for SC100

SF100

SF100 is a microcelluar open-cell frothed coating that is soft to the touch while maintaining flexibility. SF100 provides unique and functional benefits including enhanced coefficient of friction, wash durability, thermoformability, and no off-gassing. The open-cell construction of this water-based formulation allows breathability of the substrates, which minimizes undesired heat retention. 

SF100 can be directly cast on a broad range of flexible substrates (foam, nonwoven, film, foil, etc.) up to a thickness of 0.020” in continuous roll-to-roll form at a variety of full-coverage widths. This allows for thinner layers of material that cannot be achieved through traditional splitting or skiving methods and eliminates the need for an additional lamination process. SF100 satisfies the AATCC 61 requirements for 2A wash testing and can be easily maintained to ensure cleanliness. 

Download the Technical Sheet for SF100

Download the Typical Property Sheet for SF100

SF200

SF200 is a microcellular open-cell frothed coating that is cured at lower processing temperatures. Therefore, the coating can be directly cast on a broad range of flexible substrates (woven, knits, foam, nonwoven, film, foil, etc.) at thicknesses up to 0.075” in continuous roll-to-roll form at a variety of full-coverage widths. SF200 provides unique and functional benefits including enhanced coefficient of friction, wash durability, thermoformability, and no off-gassing. 

The open-cell construction of this water-based formulation allows breathability of the substrates, which minimizes undesired heat retention. This allows for enhanced 3D and tactile effects as well as thinner layers of material that may not be achievable through traditional splitting or skiving methods. SF200 satisfies the AATCC 61 requirements for 2A wash testing and can be easily maintained to ensure cleanliness. 

Download the Technical Sheet for SF200

Download the Typical Property Sheet for SF200

To learn more, please contact your Rubberlite Sales Representative or visit our SUR-fex® website at sur-fex.com