The Jacobs & Thompson Group – Rolls vs. Sheets

The Benefit of Processing Roll Goods
The art of foam skiving has witnessed some dramatic improvements over the years, none as significant as having the ability to process foams into rolled goods at the required thickness.
 
The majority of foam converting equipment restricts the cutting of parts to the edge of the raw material. This means that every sheet of foam will produce a certain amount of material loss on yield. J&T’s process ensures we consume the maximum amount of material. Here’s how it works …
 
  1. We start with foam in buns and/or rolls (pic 1)
  2. A minimal amount of the bun ends are trimmed off to produce square edges on all 4 sides the bun
  3. The trimmed buns are butt-joined snugly together using adhesive, forming a large continuous roll
  4. The bun roll is wound through one of our F&K skiving units and joined into one large loop before processing
  5. The loop is run through the F&K unit while the foam is peeled (skived) and wound onto a core at your specified thickness. (pic 2)
  6. Our rolls of continuous material incorporate usable seams, created during the joining process (pic 3)
  7. The material is now ready for adhesive lamination or finishing (pic 4)
  8. After lamination, the material is die cut to maximum yield (diagram 1- below)
 
 
 
The blue parts above, when cut out of 4 individual foam sheets, produce 2 cut strokes of 5 cavities per sheet maximum. This would yield 10 parts per sheet, 40 total parts.
 
If the 4 individual foam sheets were joined together and cut in roll form, utilizing the join seams (indicated as white lines), your yield would increase to 15 parts per sheet, 50 total parts. That’s a 25% increase! If you consider the amount of sheets required to produce your orders, the cost associated with the foam, adhesive or laminated substrates, Jacobs & Thompson can provide you with a very favourable cost solution. Don’t pay for material you won’t use.
 
If seam lines are not acceptable, Jacobs & Thompson can process foam sheets to your tolerance levels. We can also help reduce or remove seam lines at the finishing and inspection stage, if required. Its your choice. Let us know what works for you!