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Membrane Surface Laminating
Three-dimensional and flat surfacing with KYDEX sheet upgrades appearance, durability safety and cleanliness.
KYDEX sheet can produce seamless, three-dimensional furniture components that look better, last longer and are easier to produce than components surfaced with high-pressure laminates, wood veneers, paint or powder coating. Here's why:
Membrane Pressing of Routed Wood-Core Substrates Allows 3 Dimensional Design Freedom
Membrane pressing enables KYDEX sheet to conform to all top and side surfaces of flat and routed wood-core substrates, including compound curves, sharp edges and fine details—even wire management holes routed completely through the substrate. The outstanding formability of KYDEX sheet enables it to conform fully to the core, preserving sharp edges and surface detail, while maintaining uniform wall thickness on high spots, low spots, and sharp corners where other sheet products may "thin out."
The ability to conform to virtually any 3-dimensional shape overcomes 2-dimensional design constraints imposed by high-pressure laminates and wood veneers, freeing designers to create high-style furniture components having curvaceous, ergonomic shapes, as well as the durability required to withstand constant use.
In addition, membrane pressed KYDEX sheet encapsulates all but the bottom core surface (which can be laminated and heat welded at bottom edges for total encapsulation), eliminating unsightly seams that tend to separate and collect dirt, and when safety is a concern, allowing rounded corners and edges not possible with flat-laminated materials.
Shapes - You can design slopes, curves, angles and back bevels executed consistently. Shelving can take the shape of triangles, ovals, boomerangs - even surfboards! And these new eye catching designs are also quite affordable.
Typical membrane pressing applications for contract furniture components include:
• Work surfaces of desks, credenzas and workstations
• Conference tabletops
• Flat, beveled and raised panel doors and drawers of credenzas and cabinetry
• Lunchroom tabletops
• Shelving of all types
• Seating components
• Privacy panels and dividers of all types
• Seating components
Miter-Folding Produces Seamless Outside Corners
Miter-folding is accomplished by flat-laminating of KYDEX sheet to one side of a wood substrate, then routing a V-groove into the back side—deep enough to penetrate the wood but without touching the KYDEX sheet. The mitered wood edges are then coated with adhesive and hinged on the KYDEX sheet to form an outside corner that is hidden by seamless film, improving part alignment and strength while eliminating the edge lines and de-lamination problems associated with high pressure laminates and wood veneers.
Typical Miter-folding applications for contract furniture components include:
• Desk, credenza and end table cabinetry
• Peripheral cabinetry of all types
• File cabinets
• Drop-edge, high strength shelving
• Straight and tapered, high strength legs for desks, tables and stands
Any flat-laminated component requiring a sharp, seamless outside corner at virtually any mitered angle from 30° to 179° (dependant on KYDEX sheet thickness and application conditions)
Easy to Laminate, Fabricate, and Machine
In addition to being membrane pressed and Miter-folded, KYDEX sheet can be flat laminated in the same manner as high pressure laminates and wood veneers, enabling surfaces laminated with KYDEX sheet to match those that are membrane pressed and/or Miter-folded with the material.
Moreover, KYDEX sheet can be brake-formed, and fabricated into structural components using rivets, adhesives and heat welding. KYDEX sheet is also easy to saw, shear, route, drill, punch and file, and is not prone to snapping, chipping or cracking during machining, lamination and delivery, reducing re-make and repair costs dramatically.
Available in Solid Colors, Granite Patterns, Realistic Woodgrains, and Graphic Effects
KYDEX sheet is available in 34 standard colors, over 2000 developed colors, integral and capped granite patterns, integral metallic colors and realistic woodgrain patterns. Custom colors and patterns are also available at relatively low minimums, including an unlimited range of graphic effects.
A range of standard KYDEX woodgrains are matched to those of popular melamine boards and high pressure laminates, allowing different surfacing materials to be selected for the same store fixture based on each surface's anticipated the level of abuse and preferred method of production. When both sides of a component are visible, for example, it is common to membrane press, miter-fold or flat-laminate KYDEX sheet onto a melamine board of identical or complementary color or pattern. Similarly, KYDEX sheet is often applied to horizontal surfaces of store fixtures, and lower vertical surfaces likely to receive abuse, while matching or complementary melamine board or high-pressure laminate is utilized for visible undersides and/or low-wear surfaces.
Currently, KYDEX sheet is offered in offered in a range of proprietary woodgrain patterns as well as an assortment of woodgrains that match the woodgrain thermofoils of American Renolit® and Omnova Solutions®, and high pressure laminates and melamine boards of Georgia Pacific®, Uniboard®, Tafisa®, Pionite® and Roseburg®.
Renders Edges and Gouges Inconspicuous
Since KYDEX sheet in solid-colors is monolithic, and because woodgrain and other sheet patterns utilize coordinated substrate colors, any gouges or scratches are inconspicuous. And unlike the dark, unsightly edge lines associated with high pressure laminates, the integral solid colors and coordinated substrate colors of KYDEX sheet remain invisible or inconspicuous when exposed in flat-laminating applications, giving components a solid, of-one-piece appearance.
Withstands Abuse of High Traffic Environments
KYDEX sheet withstands impact, gouging and general abuse unlike any other surfacing material. It does not crack, break, chip or snap, and it is available in a range of thicknesses from .028" to .500" (0.7mm to 12.7mm) to meet anticipated levels of abuse.
Resists Harsh Cleansers, Chemicals
Tough stains, scuffs and graffiti can be removed using strong cleansers with no staining, fading or surface damage, because KYDEX sheet exhibits outstanding resistance to an exceptionally broad range of concentrated chemicals.
Overcomes Drawbacks of Conventional Surfacing Methods
Surfacing with KYDEX sheet can overcome the functional and aesthetic limitations inherent with materials traditionally utilized to surface store fixture components:
HIGH PRESSURE LAMINATES:
Chipping, cracking, seams, edge banding, T-molding, dark edge lines and 2-D limitations
WOOD VENEERS:
Edge banding, seams, softness and inconsistent staining
GRANITE, MARBLE AND SOLID SURFACING:
High material and fabrication cost
PAINTING:
Solids-only colors, scratching, chipping, blistering and high labor cost
POWDER COATING:
Chipping, lack of wood grain patterns, and high volume-per-color requirements
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