The necessity of applying protective film on aluminum profiles
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The necessity of applying protective film on aluminum profiles
The protective film is one kind of film material with a surface protection function, and it is also one of the most important products in pressure-sensitive adhesives (PSA).
The protective film is usually made of polyolefin plastic film as the base material and acrylic polymer as the base resin of the pressure-sensitive adhesive, which is processed by a coating machine.
The real meaning of the protective film is a temporary protective measure taken to prevent surface scratches during the storage, transportation and circulation of goods, or between the processing steps of the substrate.
The protective film is widely used in the surface protection of aluminum panels, aluminum-plastic composite panels, mirror effect steel plates, color panels, plexiglass panels, decorative panels, aluminum profiles, plastic steel profiles, stainless steel coils, marble materials and display screens.
Aluminum profile with protective filmThe protective film for aluminum profile is based on a polyethylene (PE) film with a specific formula, polyacrylic acid (ester) resin is used as the main material of the pressure-sensitive adhesive, and several specific adhesives are coated, slit, and processed in packaging and other processes.
The protective film is soft in nature, good in adhesion, easy to stick, and easy to peel off.
The pressure-sensitive adhesive has good stability and will not have any adverse effects on the surface of aluminum profile to be filmed.
1. The structure and material characteristics of the protective film
The protective film is generally a polyacrylate type protective film.
The basic structure of the polyacrylate type protective film (Figure 1): from top to bottom: isolation layer; printing layer; film; adhesive layer.
The structure of Polyacrylate type aluminum profile protective film1.1 Film
The film generally uses low-high-density polyethylene (PE) and polyvinyl chloride (PVC) as raw materials.
It can be obtained by extrusion molding, injection molding, and blow molding.
Because polyethylene is cheaper and more environmentally friendly, 90% of the film is made of polyethylene, mainly by blow molding.
There are many types of polyethylene, with different melting points and densities.
1.2 Adhesive
The key to the quality of the protective film is determined by the characteristics of the colloid.
There are two kinds of pressure-sensitive adhesives used in the protective film: solvent-based polyacrylate glue and water-soluble polyacrylate glue, which have different characteristics.
1.2.1 Solvent-based polyacrylate glue
Solvent-based polyacrylate glue uses organic solvents as a medium to dissolve acrylic monomers.
The colloid is very transparent, has a relatively low initial viscosity, and is very resistant to aging.
It can last up to 10 years, when exposed to ultraviolet rays, the colloid will slowly Curing.
After the film is corona treated, the polyacrylate glue can be directly coated without primer.
Polyacrylate glue is hard and has poor fluidity, so the adhesion of the protective film is slower.
Even after pressure, the glue and the surface to be attached cannot be fully contacted.
After being placed for 30 to 60 days, it will fully contact the surface to achieve final adhesion,
And the final viscosity is often 2 ~ 3 times larger than the viscosity of the paste,
If the viscosity of the protective film is suitable for the cutting, the end-user may be very laborious when tearing the film, or even cannot be torn off.
1.2.2 Water-soluble polyacrylate glue
Water-soluble polyacrylate glue uses water as a medium to dissolve acrylic monomers,
And basically has the characteristics of solvent-based polyacrylate glue,
But the glue should avoid and reduce contact with water and air to avoid residual glue.
Since water-soluble polyacrylate glue is more environmentally friendly and does not require a solvent recovery device, this glue is often used to produce protective films in developing countries.
Protective Film1.3 Characteristics of adhesive
1.3.1 Adhesion
Refers to the force required to peel the protective film from the surface to be attached after a period of time.
Adhesion is related to the material to be attached, pressure, film application time, angle and temperature when tearing the film.
Generally, with the increase of time and pressure, the adhesion will also increase, and the viscosity of the protective film should not increase too much to ensure that there is no residual glue when the film is torn.
Generally, a 180-degree peeling test is used to measure adhesion.
1.3.2 Cohesion
Refers to the strength of the inside of the adhesive.
The cohesion of the colloid as a protective film must be very high,
Otherwise, when the protective film is torn apart, the inside of the colloid will crack and cause residual glue.
Cohesion measurement method: stick the protective film on the stainless steel surface, and hang a certain weight on the protective film to measure how long it takes for the protective film to be pulled off by the weight.
If the adhesion force is greater than the cohesion force, tear off the protective film, and the bond between the glue molecules will break and cause residual glue.
1.3.3 Bonding force
Refers to the binding force of adhesive and film.
If the adhesion force is greater than the adhesion force, tear off the protective film, and the bond between the glue molecule and the film will be broken, resulting in residual glue.
1.3.4 UV resistance
Polyacrylate glue is UV resistant. After the transparent polyacrylate glue protective film is added with a UV stabilizer, its UV resistance can reach 3 to 6 months.
Generally, climate simulation equipment is used to test the UV resistance of the protective film.
The temperature and radiation intensity is adjusted and the condensed water is used to imitate climate change.
Every 3 hours of high humidity environment and 7 hours of ultraviolet radiation is a cycle, and a 50-hour cycle experiment is equivalent to approximately leaving it outdoors for a month.
2. Production of protective film
2.1 Production of protective film
In the heated drum, the polyethylene particles are pushed by the screw to the round die head, and compressed air will blow the molten liquid, through the air cooling, rolled into a film.
The properties of the blown film in the transverse and longitudinal directions are different.
The elongation in the machine direction of the protective film is generally greater than 180%, and the elongation in the transverse direction is generally greater than 380%.
However, the elongation is inversely proportional to the mechanical strength.
If the elongation is too large (such as greater than 500%), the mechanical strength of the film will often be very low, which will easily cause the protective film to be damaged during transportation and handling,
And when unwinding, the protective film is easily stretched, after cutting, the protective film will rebound and warp.
The production of protective film2.2 Coating of adhesive
The corona-treated film can be directly coated with polyacrylate glue, no primer is required.
Then the protective film passes through a long air heating channel (80 ~ 120°C) to ensure that the water or solvent is evaporated, and then the protective film is cooled by a cooling roller, and finally rolled up.
2.3 Rewinding, slitting and storage
The protective film is directly rewound on the coating machine to the length required by the customer.
If the customer needs the protective film to have a beautiful appearance and no bubble wrap, it can be rewinded with a high-quality rewinder to ensure that there is no air wrap.
For short protective film (under 500 meters), a straight knife can be used for slitting. Over 500 meters, the heat generated when slitting with a straight knife may melt the polyethylene, making it difficult to unwind, or even tear the film.
The protective film can generally be stored for 12 months at a room temperature of 30°C and no direct sunlight.
The higher the temperature, the shorter the storage period. For every 10°C higher, the storage period will be reduced by half.
3. Application of protective film
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Generally, there is a curved roll (Banana roll) on the aluminum profile film application machine to open the protective film to avoid bubbles and wrinkles.
For a low-viscosity protective film, the lower the tension when it is unwound, the better it will be, otherwise, the edges will be warped.
The filming temperature should be higher than 10°C, and the tearing temperature should also be higher than 10°C.
The peeling force is closely related to the speed and angle of the tearing film.
Too low a temperature will harden the protective film and warp the edges.
In this case, apply hot air to heat first, or produce in an air-conditioned workshop.
The hardness of the rubber pressure roller is generally 60A.
When the protective film is rewinding, more or less air is wrapped in the adhesive, causing the rubber surface to be slightly uneven.
If the rubber pressure roller is too soft, it will not be able to effectively drive out the air bubbles and flatten the adhesive.
If the rubber pressure roller is too hard, the pressure generated will not be enough to make the glue and aluminum profile effectively contact, and it is easy to cause the edge of the protective film when edge cutting.
Since the rubber pressure roller will gradually age and harden during use, the rubber roller should be checked and replaced frequently.
Aluminum profiles film application machine4 Application of protective film in aluminum industry
The protective film is a layer of plastic film sticking to the aluminum material.
The purpose is to protect the surface of the aluminum profile from damage during a series of processes such as handling, storage, transportation, processing, and installation.
After the aluminum profile is installed, the engineering team tore it off, so that the surface of the aluminum profile is as smooth as new, and it has the desired decorative effect.
There are many types of aluminum profiles on the market, and the surface treatment technology of aluminum materials is constantly improving.
Various aluminum surface treatment technologies include: mechanical polishing, chemical polishing, anodizing, electrophoretic painting, chemical coloring, fluorocarbon spraying, electrostatic powder coating, wood grain effect sublimation treatment, etc.
Different aluminum profile surfaces need to be selected differently Adhesive protective film.
The protective film products generally have 4 series of low viscosity, medium viscosity, high viscosity and extra high viscosity; the colors are transparent, milky white, blue, black and white, etc.;
The thickness is 30 ~ 200μm, so it needs to be selected different protective films according to the different surfaces of the aluminum profile.
According to the different surfaces of the aluminum profile and film pressure, the viscosity rise speed is different,
Generally, the protective film should be left for enough time before peeling off the protective film to determine whether the viscosity is appropriate.
For a given surface, it is extremely important to choose the appropriate adhesive and viscous protective film.
The further processing steps are the key to determining the viscosity. The subsequent processing generally includes cutting, bending, drilling, stamping, etc.
Generally, low-viscosity protective films are used for smooth surfaces, such as mechanical polishing and chemical polishing aluminum profiles.
Medium-viscosity protective films are used for medium-rough surfaces, such as anodizing, electrophoretic coating, chemical coloring, fluorocarbon spraying, and powder-coated aluminum profile.
Use high-viscosity protective film for very rough surfaces, such as electrostatic powder coated aluminum profiles.
If laser cutting is required, because the protective film shrinks due to heat, you should use a super-high-viscosity protective film.
In addition to viscosity, users also need to test the tensile strength and elongation of the protective film to ensure that the flexibility and strength of the protective film can meet the requirements of the application.
Aluminum profiles Automatic film applicator machine5. Conclusion
During transportation, storage, processing, and assembly of aluminum materials, the surface of the aluminum profile needs to be protected to prevent harmful gases, microbial corrosion, dust pollution, mechanical scratches, scratching, etc.,
So that the surface of the product retains the original high smoothness, improves the yield of secondary processing,
In addition, it can also be used for temporary protection in electroplating, printing, coating, printing and dyeing, etc.
The most commonly used method to protect the surface of the aluminum profile is to put a protective film on the surface of the material to be protected.
The value of the protective film in the aluminum industry is very small, which is only an auxiliary material used by the manufacturer.
However, if the protective film is used improperly or does not meet the requirements, the risk is that it will not only fail to protect but may damage it.
The surface quality of the product brings tangible material loss and intangible brand image loss to users, which ultimately affects the product manufacturer’s price position and product sales.
The correct application of the protective film not only improves the appearance quality of the aluminum profile, facilitates material processing, increases the utilization rate of the material, reduces the production cost of the product, but also improves the brand image of the company.
Brightstar Aluminum Machinery provides not only aluminum profile film sticking machine for our customers, but also aluminum profile packaging solution, aluminum profiles automatic film applicator machine, hot shrink packaging machine, aluminum profiles wrapping machine and aluminum profiles bagging machine.
Contact us now for your aluminum profiles packaging solution!
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This post was originally published August 2014 and has been updated with additional content, resources, images, etc.
Homeowners and DIY enthusiasts have their pick when it comes to types of tape for household projects. The question is: which is the right type of the tape to get the job done? With so many choices, it can be difficult to know which tape is appropriate for your particular home improvement project.
We’ve created a quick visual guide to choosing the right tape for your next home improvement project to help make the decision processes easier, as well as a short animated video to highlight some of the differences. Check out these resources below.
Not All Tape is the Same
There’s a reason why there are so many different types of tape. Each type of tape is designed to help you accomplish a specific task or work best in a specific scenario. Using the wrong tape for the job can lead to real problems, and can even create a safety hazard or leave unwanted hard to remove residue on floors, window frames et. You wouldn’t want to use duct tape for masking or scotch tape for electrical projects.
Pay Attention to Features
The width and thickness of your tape matters, but so does temperature rating, conductivity, and level of water resistance of your tape. If working on an outdoor project, make sure the tape you choose is thick and ideally water-resistant. For indoor electrical projects, thinner, non-conductive tape is best.
Tape Versus Sealant
For some plumbing and HVAC projects, tape may not be the best choice. In certain cases, using a sealant or mastic can provide a stronger, longer-lasting, more resistant solution than tape. The downside to sealant and mastic is that it can be messy and difficult to work with, making it much less convenient than tape. The only choices for HVAC duct work should be mastic or foil tape.
Ask a Pro
If you’re still unsure of which type of tape to use for your home improvement project, ask a home remodeling contractor or other building professional for some guidance. Big-box home improvement centers, hardware, or paint stores are almost guaranteed to carry the tape you need, and you can always get input from store employees as well. Don’t be afraid to ask for help!
Ducts within your home can spring leaks for a wide variety of reasons, and at any time, making it a somewhat tough problem to anticipate. That’s why it’s important to have your HVAC system regularly maintained. Still, if you suddenly have a higher-than-average energy bill, your air conditioner or furnace seems to have to work harder to cool or heat your home, or some rooms are noticeably different in temperature or stuffier than others, you may have leaks in your ducts. These leaks within the home can be costly, make your appliances wear out faster, make your home less comfortable, and waste energy over time. In fact, leaky ducts can be one of the largest energy wasters in the home that hinders your attempts at cutting down your energy bills.
Luckily, the ducts that run through your home can be sealed with either foil tape or duct mastic, and every DIY master or contractor has their own preference for what they use when working on residential ducts. Both of these options have their benefits and drawbacks, and just like any project, a professional assessment can go a long way toward ensuring the work is done right and will last well into the future. Here are a few pros and cons of both approaches.
Duct mastic is a gooey material that can be easily applied using a paintbrush and is readily available at most home improvement stores. Mastic can be applied generously to duct joints and leaks and is a great option for ensuring that the seal will not fail over time. Probably the biggest upside of using mastic is that it is a great choice for those hard-to- reach areas and sharply angled duct joints.
Unlike with using tape, you do not necessarily have to make sure the area is clean before using mastic. There is also no risk of mastic delaminating or stripping off over time. The biggest downside to using mastic is that it can be messy when you are applying it. We always recommend wearing old clothes and rubber gloves when sealing ducts with mastic.
To fill in holes and gaps, flat metal tape coated with an adhesive is a great choice. Foil tape should only be used for sealing. Quality tapes can be hard to find and must often be purchased at specialty heating stores. Purchasing low quality tapes from home improvement stores is not recommended because there is a high risk of failure after only a few years.
Professional quality tape will stand the test of time. Tapes are much cleaner than mastic, but they are a bit more expensive to purchase. It is also recommended that you clean the area before using any type of tape to seal. For long sections of hard, round ductwork, taping can be an acceptable practice, but irregular surfaces and dirt or dust can compromise the application.
Below we’ve included a nice comparison chart by 3M that details some different types of sealing and insulating mastic tape.
The term “duct tape” is quite misleading. Although the name of this product makes it sound perfect for the job at hand, never seal ducts with duct tape. Duct tape is not approved for use on ducts and, despite the fact that it works great for a variety of heavy-duty projects, doesn’t stand up to the conditions of an HVAC system. At Murray Lampert Design, Build, Remodel, we prefer to use duct mastic to seal and repair ducts. We like it because it stands the test of time and makes it easy to fill in those irregularly shaped areas of ductwork. If you have a leaky duct to repair, consider your unique circumstances and which material you feel most comfortable working with.
A word of advice with either option: choose a high-quality product. Again, don’t hesitate to ask someone at a home improvement store for their recommendation on the best product for the job you’re trying to accomplish. For quality HVAC installations and service in San Diego, we recommend Mauzy Heating & Air Conditioning.
Also known as “insulating tape,” electrical tape is made of plastic (most commonly vinyl) and is used to insulate electrical wires. It comes in a variety of colors to indicate voltage. Electrical tape is also great for labeling, grip enhancement, and cable installation.
Duct tape is considered the most versatile type of tape, and is a staple of many homeowners for an array of DIY projects. Modern duct tape is made with woven fabrics to provide strength & flexibility. It can be used just about anywhere heavy-duty adhesion is needed, although it is susceptible to high heat and leaves a residue when removed. As we’ve mentioned above, duct tape should NOT be used to seal HVAC ducts in your home. Mastic or foil tape is a better option for that job.
Something else to clarify here is the difference between “duct tape” and “Duck Tape.” Duck Tape is a specific brand of duct tape, as is Gorilla Tape, 3M, and many others.
If you’re tackling an HVAC job at home, aluminum foil tape should be your go-to. Foil tape is flame resistant, holds up in extreme temperatures, and sticks strong in high humidity. If you’d rather not mess with duct mastic to seal up your HVAC system, aluminum foil tape is a solid alternative.
Masking, or painter’s tape, is a paper-based, multi-use tape that is primarily used to mask off areas during interior and exterior painting projects. Key characteristics include easy tearing and low-grade adhesive to reduces damage and residue on surfaces once the tape is removed.
This video by Consumer Reports does a good job of outlining some of the best painter’s tape brands.
As the name suggests, carpet tape is mainly used to tack down carpets and keep area rugs in place. Carpet tape is flexible, durable, moisture-resistant, and usually featured adhesive on both sides. One-sided carpet tape is used primarily to join two smaller pieces to form a large section of carpeting.
According to Can-Do National Tape, there are actually four distinct varieties of packing tape: carton sealing tapes, printed tapes, gummed tapes, and label protection tapes. Each of these varieties is meant to work with certain package weights, sizes, and shipping methods. Most homeowners will be just fine using the clear plastic packing tape most of us are familiar with - also known as “Polypropylene Tape.” It’s strong, durable, and resistant to tearing or breaking during shipment.
Renters are probably the most familiar with mounting tape, which is a double-sided tape used to hang, mount, or display things on interior walls without causing any damage. Mounting tapes are usually foam-based, and they vary in size and by the amount of weight they are able to support and secure to a surface.
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For more stainless steel protective filminformation, please contact us. We will provide professional answers.