The problems encountered in the vacuum plastic coating process and the solutions

The problems encountered in the vacuum plastic coating process and the solutions

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The vacuum plastic coating process, also known as vacuum metallizing or vacuum deposition, can encounter various challenges and problems during its execution. These issues can impact the quality of the coated products and the efficiency of the manufacturing process. Here are some common problems encountered in the vacuum plastic coating process and their potential solutions:
Pinholes or Porosity in Coating:
Problem: Small holes or pores in the coating can lead to reduced barrier properties and aesthetics.
Solution: Improve the cleanliness of the substrate surface, adjust the coating parameters, and ensure proper degassing of the vacuum chamber to minimize contamination and porosity.
Uneven Coating Thickness:
Problem: Variations in coating thickness across the substrate can result in inconsistent appearance and performance.
Solution: Maintain proper control over deposition rates, substrate rotation or movement, and coating source positioning to ensure uniform deposition.
Adhesion Issues:
Problem: Poor adhesion of the coating to the substrate can result in delamination or flaking.
Solution: Pre-treat the substrate surface with techniques like plasma cleaning or corona treatment to improve adhesion. Ensure proper substrate cleaning and preparation.
Contamination and Impurities:
Problem: Contaminants in the vacuum chamber or on the substrate can lead to defects in the coating.
Solution: Maintain a clean environment within the vacuum chamber, regularly clean the chamber and fixtures, and use high-purity source materials.
Stress and Cracking:
Problem: High residual stress in the coating can lead to cracking or peeling.
Solution: Optimize deposition parameters, such as temperature and deposition rate, to reduce stress. Use stress-relief layers if necessary.
Substrate Warping or Deformation:
Problem: Some plastics may deform or warp under the high vacuum and temperature conditions.
Solution: Choose substrates that are suitable for vacuum coating or implement temperature control methods to minimize substrate distortion.
Phenomenon 1: Bubbling in the groove
Reason analysis:
1. The temperature or pressure does not meet the requirements, resulting in false suction;
2. Insufficient adhesive amount, insufficient spraying amount, or adhesive leakage from the board;
3. Insufficient preheating (softening PVC film) or blistering time (forming time);
4. After vacuum molding, remove the pressure before the temperature drops.
5. The heat resistance of the adhesive itself is not sufficient.
Solution:
1. Increase temperature or vacuum;
2. Increase the amount of glue applied and select high-quality boards;
3. Increase preheating or molding time;
4. After vacuum molding, the temperature should be cooled to room temperature or slightly higher before withdrawing the vacuum.
5. Use with curing agent.
Phenomenon 2: Local blistering
Reason analysis:
1. Uneven glue spraying results in a small amount of local glue, leading to a decrease in bonding strength;
2. The problem with PVC film is that it contains plasticizers, which can easily migrate to the surface during aging or heating, affecting the bonding strength;
3. There is a problem with the heating pipe inside the blister machine, causing uneven temperature.
Solution:
1. Try to ensure a uniform amount of adhesive spraying;
2. Use high-quality PVC film;
3. Timely maintenance of equipment.
Phenomenon 3: Unable to hold or shrink the edge
Reason analysis:
1. When vacuuming, the side temperature is too low or the vacuum degree is insufficient;
2. Insufficient temperature resistance of adhesive;
3. After vacuum molding, remove the pressure before the temperature drops.
Solution:
1. Increase temperature or vacuum;
2. Use with curing agent;
3. After vacuum molding, the temperature should be cooled to room temperature or slightly higher before withdrawing the vacuum.

 

How to choose PVC wood grain film?

How to choose PVC wood grain film?

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PVC wood grain film is mainly used in the furniture, cabinet, and decorative board industries. It can be surface veneered or vacuum molded, and the processing is very fast, with good shaping degree and a bright and bright surface. There is no need to spray Western paint on the surface anymore. It has excellent water resistance, excellent corrosion resistance, and is easy to clean. It is a new type of environmentally friendly decorative material.
PVC wood grain film is less prone to whitening, has less shrinkage, has fewer crystal impurities compared to other products, and has good flatness, clear color, good waterproof and moisture-proof performance, good flame retardant performance, good weather resistance, strong stamping resistance, wear resistance, good plastic flat adhesion effect, and is not easy to fade when exposed to indoor and outdoor sunlight. It also has the characteristics of vacuum suction molding that does not eliminate lines and has no white edges.
PVC wood grain film is a new type of decorative material made from high molecular polymer as raw material, with various additives added, and processed through rolling, lamination, and wood grain printing. It can be compounded with substrates such as wood, plastic board, aluminum board, iron board, etc. It is commonly used as decorative materials and is widely used in the production of veneers for office furniture, cabinet doors, wardrobes, wooden doors, woodwork products, speakers, and other decorative materials.
There are many types of PVC wood grain films, such as walnut, cherry, oak, beech, maple, teak, pine, sandalwood, pear, etc., and each wood grain has many colors to choose from.
Its application prospects are also very broad: due to the relatively free selection of the product, there is no need to spray paint the surface, which to some extent saves processing costs. Well shaped, with a bright and beautiful surface, rich colors, pure and vibrant color, and realistic wood grain. It has strong water resistance, corrosion resistance, and scratch resistance. Long term use can also ensure no deterioration. Cleaning is relatively convenient, suitable for all households, and has become the mainstream panel of European cabinets, gradually gaining popularity among domestic users. It is also a new type of environmentally friendly decorative material.
Choosing the right PVC wood grain film involves considering several factors to ensure that it meets your specific needs and requirements. Here are some steps and factors to consider when selecting PVC wood grain film:
1.Application and Purpose:
Determine the purpose of using the PVC wood grain film. Is it for furniture, cabinetry, flooring, doors, or another application? Different applications may require specific film characteristics.
2.Substrate Material:
Consider the type of substrate material (e.g., MDF, particleboard, plastic, metal) on which the film will be applied. Compatibility with the substrate is crucial for adhesion and durability.
Design and Aesthetic Preferences:
Decide on the desired wood grain pattern, color, texture, and finish. PVC wood grain films come in a wide range of designs, including various wood species and finishes like matte, glossy, or textured.
3.Quality and Durability:
Assess the quality and durability requirements for your specific application. Some applications, such as high-traffic flooring or outdoor use, may require more robust and wear-resistant films.
Environmental Considerations:
Take into account any environmental or safety considerations. Ensure that the chosen PVC film complies with relevant regulations and standards.
4.Adhesive Type:
PVC wood grain films often come with different adhesive types, such as hot melt adhesive or pressure-sensitive adhesive (PSA). Choose the adhesive type that suits your application and installation process.
5.Thickness:
Determine the thickness of the PVC film. Thicker films may provide greater durability and resistance to wear and tear.
6.Flexibility and Formability:
Consider the flexibility and formability of the film. Some applications may require a film that can conform to curved or irregular surfaces without cracking or tearing.
7.UV Stability:
If the film will be exposed to sunlight or outdoor conditions, check its UV stability and resistance to fading.
8.Fire Resistance:
If fire resistance is important for your application, ensure that the PVC film meets the necessary fire safety standards.
9.Ease of Installation:
Evaluate the ease of installation and whether it requires specialized equipment or expertise. Some films may be more DIY-friendly than others.
10.Supplier and Manufacturer Reputation:
Choose a reputable supplier or manufacturer with a track record of providing high-quality PVC wood grain films. Check for customer reviews and references.
11.Sample Testing:
Whenever possible, request samples of the PVC wood grain films you’re considering. Testing samples can help you assess their suitability for your specific application.
12.Cost Considerations:
Compare the cost of different PVC wood grain films and factor in your budget. Keep in mind that higher-quality films may have a higher initial cost but can provide long-term benefits in terms of durability and aesthetics.
13.Warranty and Technical Support:
Inquire about warranties and technical support provided by the supplier or manufacturer. A good warranty can provide peace of mind regarding product quality and performance.
By carefully considering these factors and conducting thorough research, you can choose the right PVC wood grain film that best meets your project’s requirements and ensures a successful and aesthetically pleasing outcome.

 

How does the membrane press work?

How does the membrane press work?

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The medium density substrate is processed into various linear shapes and then covered with PVC films of various brightness, colors, and textures, making the products rich and colorful, creating a wide range of choices for consumers. However, the quality of products manufactured using this technology varies greatly. The reasons for these differences are not only due to the factors of the substrate and decorative material PVC itself, but also the control of process parameters during the processing process.

1、 Working principle of membrane press

By utilizing the plasticity of PVC and adjusting and controlling the membrane pressure time, equipment chamber temperature, and air pressure, PVC is heated and pressurized to coat the surface of the workpiece.

2、 The working process of the membrane press

(1) Place the workpiece on the workbench;

(2) The workbench enters directly below the heating plate;

(3) Close the heating plate with the workbench;

(4) The air between the heating plate and the silicone film is extracted, and the silicone film is adsorbed onto the heating plate for heating;

(5) After reaching the set time, compressed air is injected between the heating plate and the silicone film. The silicone film is in close contact with PVC, and the workpiece and PVC are heated. At the same time, PVC is softened, and the temperature at the edge of the plate reaches the activation temperature of the adhesive;

(6) The air between the workbench and PVC is quickly extracted to form a vacuum, and then compressed air is injected between the PVC and the heating plate. PVC is wrapped on the plate under the set pressure and temperature.

A membrane press, also known as a vacuum membrane press or membrane vacuum press, is a machine used in woodworking and the manufacturing of laminated products. It is primarily used to apply decorative or functional laminates, veneers, and films onto various substrates like wood, MDF (Medium-Density Fiberboard), particleboard, and foam. Here’s how a typical membrane press works:

Preparation:

First, the operator prepares the substrate (e.g., a wooden panel or piece) by applying adhesive to it. This adhesive will bond the decorative material or laminate to the substrate when subjected to heat and pressure.

Laying the Decorative Material:

The decorative material, which is typically a flexible PVC or thermoplastic film with a decorative pattern (such as wood grain or solid color), is placed over the adhesive-coated substrate. This material will become the visible surface of the finished product.

Positioning in the Press:

The substrate and decorative material are then placed in the membrane press. The press consists of a chamber or frame with a flexible, heat-resistant membrane or silicone bag suspended above it.

Creating a Seal:

The membrane is lowered to make contact with the decorative material and substrate. It should form a tight seal around the edges to create an airtight chamber.

Vacuum and Heat:

The press is equipped with a vacuum system. When activated, it removes the air from the chamber between the membrane and the substrate. This creates a vacuum or negative pressure inside the chamber.

Heating Elements:

The press also contains heating elements, such as electric heating panels or infrared lamps. These elements generate heat and are positioned above or below the membrane.

Activation:

The vacuum and heat are activated simultaneously. The vacuum draws the flexible membrane tightly around the decorative material and substrate, pressing them together with even pressure. At the same time, the heat activates the adhesive, causing it to bond the decorative material to the substrate.

Curing and Cooling:

The heating elements maintain the desired temperature for the adhesive to cure properly. This curing process may take a few minutes. After curing, the temperature is gradually reduced to allow the bonded materials to cool and set.

Release and Removal:

Once the curing and cooling process is complete, the vacuum is released, and the flexible membrane is lifted. The bonded decorative material is now securely attached to the substrate, conforming to its shape.

Trimming and Finishing:

The finmming and Finishing:ished product, with the decorative material firmly adhered to the substrate, may undergo additional finishing processes such as edge trimming, sanding, or further machining to achieve the desired final dimensions and appearance.

The membrane press ensures a consistent and even application of decorative materials, eliminating wrinkles, air bubbles, and other defects that can occur with manual or less controlled laminating methods. It is widely used in the production of furniture, cabinetry, doors, wall panels, and other laminated products where high-quality surface finishes are essential.

 

Differences between PVC film and ordinary adhesive film

Differences between PVC film and ordinary adhesive film

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PVC film and ordinary adhesive film are both used for various applications, but they have distinct differences in terms of material composition, properties, and applications. Here are the key differences between PVC film and ordinary adhesive film:

Material Composition:

PVC Film (Polyvinyl Chloride Film): PVC film is typically made from polyvinyl chloride, a type of plastic material. It is a thermoplastic polymer known for its durability and flexibility.

Ordinary Adhesive Film: Ordinary adhesive films can be made from a variety of materials, including paper, plastic, fabric, or metal foils, depending on the intended application.

Adhesive Layer:

PVC Film: PVC films often do not have a built-in adhesive layer. They are typically used in conjunction with adhesives like contact cement or specialized laminating adhesives to bond them to surfaces.

Ordinary Adhesive Film: Ordinary adhesive films have an adhesive layer on one side, which allows them to stick to surfaces without the need for additional adhesives. The type of adhesive can vary, including pressure-sensitive adhesives, hot melt adhesives, or solvent-based adhesives.

Applications:

PVC Film: PVC films are commonly used for decorative purposes, such as laminating furniture, cabinetry, doors, and wall panels. They are also used in packaging, signage, and as protective coatings for various surfaces.

Ordinary Adhesive Film: Ordinary adhesive films have a wide range of applications, including label printing, packaging, graphic design, industrial labeling, and more. They can be used for bonding, labeling, covering, and sealing various surfaces and materials.

Appearance and Finish:

PVC Film: PVC films often have a decorative appearance, with various textures, patterns, and colors, making them suitable for enhancing aesthetics in applications like interior design and decor.

Ordinary Adhesive Film: Ordinary adhesive films may have a plain or printed appearance, depending on their intended use. They are often used for functional purposes, such as labeling or protection.

The main component of PVC film is polyvinyl chloride, and other components are added to enhance its heat resistance, toughness, ductility, etc. The top layer of this surface facial mask is paint, the main component in the middle is PVC, and the bottom layer is back coating adhesive.Ordinary adhesive film is directly applied to the surface of the board with glue at room temperature, so after one or two years, the film is prone to detachment. PVC film, on the other hand, is pressed onto the surface of the board using a specialized vacuum press at a high temperature of 110 degrees Celsius, making it less prone to detachment. Although PVC film has excellent quality assurance, some people may say that PVC is a chemical product after all, and it cannot be compared to natural materials, which cannot eliminate toxicity and odor, and cannot avoid causing harm to the environment. The fact is that this is not the case. This is because the raw materials for producing PVC films are specially extracted, and toxic substances are completely extracted. Therefore, PVC is completely non-toxic and odorless, and has no irritation to the human skin or respiratory system. For those who are allergic to wood and paint, using PVC film packaging for furniture or kitchenware is very suitable. By using PVC film as decorative film, people can use a large amount of medium density board, particle board, plywood, and fiberboard, reducing the amount of wood used.

 

How to install PVC decorative film?

How to install PVC decorative film?

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How to install PVC decorative film?

 Substrate adjustment

1. Substrate – Be sure to grind the flat page to a fine and thoroughly touch and insert it thoroughly. If there is oil stains, clean it with solvent.

The temperature of homework is 15 ° C to 20 ° C, and in principle, construction can be carried out at 5 ° C.

 Plane construction

1. The substrate treatment is as described above.

2. Determination of position: The position to be placed first is fixed with leftover materials.

3. Before pasting, peel off the paper by about 10 centimeters, and use a soft cutting blade to gently press the air out from above.

 

4. If there are small bubbles, the blade can be used to puncture them and then the air can be pushed out with a cutting blade. It is best to wrap the cutting blade with a soft and damp cloth to avoid damaging the surface.

Right angle construction

1. Please apply primer to the substrate and dry it thoroughly before smoothing it out

When the flat part is constructed to the right angle part as described above. According to the following figure, the construction can be carried out by gently pressing in the order of the top, or by heating and pressing with an electric hair dryer. At this point, gloves can be worn or a soft cloth can be gently pressed with fingers to achieve good results.

4、 Double right angle construction. The substrate treatment is the same as before.

2. Paste: First, attach A and fold it onto side B, then fold side B onto the quilt and cut off any excess film (note that if the dot printing part of A and B overlaps, it will protrude here. For aesthetic reasons, it is not necessary to fold A to side B).

Construction method for pentagonal and cubic curved surfaces

1. The corners of the substrate should be thoroughly coated with primer (3-4 times), dried, and ground with # 400 sandpaper until smooth and smooth,

2. Use an electric hair dryer to fully heat the corners. When the Polaroid film has appropriate softness, pull it down from the top of Figure 12A and press it down in sequence B’C’D’E ‘.

3. Please pay attention to slowly pulling from the top in the order of Ai B’C’D’E (less than one centimeter at a time), press with your fingers, then move to B “C’D’E and repeat from A to the bottom. Do not be impatient and pull to the bottom at once, which will cause wrinkles and make it difficult to handle.

4. When heating and pulling downwards, it is advisable to extend your fingers deep inside (do not only pull towards the edge; pull and press on one side to achieve good construction results).

 

What is pvc film

What is pvc film ?

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We may often hear the concept of pvc film in our lives, but what it specifically represents may not be understood by many people, and they still stay in the vague understanding of cling film and plastic film. In fact, pvc products have been widely used in our lives, especially in architectural decoration. Many of the furniture we see are covered with a layer of PV film, which can not only make the appearance of the furniture more beautiful and generous, but also enhance the service life of the furniture.

What is PVC film?

PVC film (polyvinyl chloride film), which is made of polyvinyl chloride resin and other modifiers through calendering or blow molding. Generally, the thickness is 0.08~0.2 mm, some thicker than 0.25 mm are called PVC sheets. Plasticizer, stabilizer, lubricant and other functional processing aids are added to PVC resin, and then rolled into film.

Main components of PVC film:

PVC resin:40%~70%, plasticizer:10%~50%

Stabilizer:1%~10%, filler:1%~30%

Colorant : 1%~10%

Characteristics of PVC film:

PVC film is insoluble in water, alcohol, gasoline, and can swell or dissolve in ether, ketone, chlorinated aliphatic hydrocarbons and aromatic hydrocarbons. At room temperature, it is resistant to concentrated hydrochloric acid, 90% sulfuric acid,  50%-60% nitric acid, and caustic soda solution below 20%.

Properties of PVC film:

Ordinary adhesive film is directly pasted on the surface of the board with glue at room temperature,  after one or two years, the film may fall off easily. The PVC film is attached to the surface of the board at a high temperature of 110 degrees by a special vacuum laminating machine, so it is not easy to fall off.

Although PVC film has excellent quality assurance, some people may say that PVC is after all just a chemical product l, so it is not as good as natural materials, it also  can not eliminate toxicity and odor, and it will inevitably cause damage to our environment. In fact, they are wrong ,because the raw materials for the general production of PVC film are specially refined, and the toxic substances are completely extracted.

Therefore, PVC is completely non-toxic and tasteless, and has no irritation to human skin or respiratory system. For those who are allergic to wood and paint, furniture or kitchen utensils packed with PVC film are extremely  suitable. By using PVC film as a decorative film, people can use a large number of medium-density boards, particle boards, plywood and fiberboards, instead of the wood using to reduce  damage to forests and the environment.

From this perspective, PVC film has made a great contribution to the protection of the ecological environment. The quality of PVC is not inferior to other alternatives, and the cost is cheaper than these materials.

The PVC film industry is developing rapidly all over the world and has broad prospects. Everyone is optimistic about the potential and the benefits to the environment of PVC film .With its excellent and special performance, PVC film proves to the world that its role and status cannot be replaced by any other products. Social development Need it, environmental protection needs it, it is the inevitable trend of civilization progress of our human society.

Qisheng is a professional pvc film manufacturer from China that offer both standard density and customized density pvc film per customer’s requirements. If you are looking for high quality pvc film for your projects, please don’t hesitate to contact [email protected] .

 

 

 

 

How to calculate density of pvc film ?

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If you’re working with PVC film, it’s important to know how to calculate its density. This will help you determine the best way to use the material and ensure that your project is a success. Here’s a quick guide on how to do it.

PVC film is a versatile and durable material that can be used for a variety of applications

PVC film is a reliable and multi-use material with so many possibilities. It’s no wonder it has become the go-to choice for those looking for an economical and easy way to make their product or project stand out. This versatile and durable material can be used for almost anything, from protecting windows to wrapping around furnishings, decorations, or signs. Plus, it can even be printed on so you can make your projects completely custom! Whether you’re crafting something on your own or stocking up as a business owner, PVC film is the perfect option for flexibility and affordability.

The density of PVC film can be calculated using the following formula: (mass of PVC film / volume of PVC film) x 1000 = density of PVC film in g/cm3

PVC (polyvinyl chloride) film is a type of plastic and is used for a wide variety of purposes, ranging from window frames to packaging. PVC film has a specific density which can be calculated using the relevant formula. The formula takes into consideration the weight and the volume of the PVC and provides an accurate result. The ability to calculate the density of PVC film accurately is important in order to select an appropriate product with the specified characteristics according to the specific application requirements.

The formula used to determine this important value involves dividing the mass of the PVC film by its volume, then multiplying the outcome by 1000 to obtain the density in g/cm3. By understanding this formula and its application, individuals analyzing PVC films can accurately report their properties and make more informed decisions about how they should be used. Determining the final density is fundamental for improving functionality, expanding knowledge, and driving innovation for future vinyl films.

This information can be useful when choosing the right type of PVC film for your project

When it comes to PVC film, the choices available can seem overwhelming. The key to selecting the film that’s best suited for your project is understanding what the various options have to offer and this information is invaluable in making an informed decision. PVC film can be found in a vast range of sizes, finishes, thicknesses and colours so it’s important to have as much knowledge about each type as possible — before committing to one — to ensure you get exactly what you’re looking for. Understanding this data can help make sure you pick the type of PVC film that’s just right for your project and will provide you with great results every time.

Keep in mind that the density of PVC film may vary depending on the manufacturer

When researching a purchase of PVC film, it is important to keep in mind that the density of the product may vary depending on the manufacturer. This variation can significantly alter the performance of the product and could ultimately change the intended use of the PVC film. As such, customers should always consult reviews or do thorough research when selecting a supplier to ensure they are investing in superior quality materials. Understanding variations in density across multiple manufacturers will also help buyers make financially savvy decisions as they select products with optimal weight-to-strength ratios.

Qisheng is a professional pvc film manufacturer from China that offer both standard density and customized density pvc film per customer’s requirements. If you are looking for high quality pvc film for your projects, please don’t hesitate to contact [email protected] .