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Introduction to Vacuum Aluminum Plating Process
Release time:
2022-01-10
Vacuum aluminum plating is to heat and melt aluminum metal in a vacuum state until it evaporates, and aluminum atoms condense on the surface of polymer materials to form an extremely thin aluminum layer. Vacuum aluminum plating requires that the substrate surface is smooth, flat, and uniform in thickness; the stiffness and friction coefficient are appropriate; the surface tension is greater than 38dyn/cm'; the thermal performance is good and can withstand the heat radiation and condensation heat of the evaporation source; the moisture content of the substrate is less than 0.1%. Commonly used aluminum-plated substrates include polyester (PET), polypropylene (PP), polyamide (N), polyethylene (PE), polyvinyl chloride (PVC) and other films. Process requirements: The vacuum degree must not be lower than 10-3Pa to avoid brown stripes or uneven thickness of the aluminum layer; control the system tension, turn on the cooling system to avoid the film from being stretched and deformed by heat; accurately control the winding speed (280-320m/min), aluminum feeding speed (0.4-0.7m/min, 2mm diameter aluminum wire) and evaporation boat heating current to obtain the aluminum layer thickness required by the product (100-300A); a certain amount of primer can be applied to the film in advance and fully dried, and then vacuum aluminum plating can improve the bonding force between the aluminum layer and the film. Then apply a certain amount of protective resin on the aluminum film to prevent the aluminum layer from oxidizing and deteriorating. The aluminum-plated film formed by this process is friction-resistant and not easy to deteriorate.
Vacuum aluminum plating is to heat and melt aluminum metal in a vacuum state until it evaporates, and aluminum atoms condense on the surface of polymer materials to form an extremely thin aluminum layer. Vacuum aluminum plating requires that the substrate surface is smooth, flat, and uniform in thickness; the stiffness and friction coefficient are appropriate; the surface tension is greater than 38dyn/cm'; the thermal performance is good and can withstand the heat radiation and condensation heat of the evaporation source; the moisture content of the substrate is less than 0.1%. Commonly used aluminum-plated substrates include polyester (PET), polypropylene (PP), polyamide (N), polyethylene (PE), polyvinyl chloride (PVC) and other films.
Process requirements: The vacuum degree must not be lower than 10-3Pa to avoid brown stripes or uneven thickness of the aluminum layer; control the system tension, turn on the cooling system to avoid the film from being stretched and deformed by heat; accurately control the winding speed (280-320m/min), aluminum feeding speed (0.4-0.7m/min, 2mm diameter aluminum wire) and evaporation boat heating current to obtain the aluminum layer thickness required by the product (100-300A); a certain amount of primer can be applied to the film in advance and fully dried, and then vacuum aluminum plating can improve the bonding force between the aluminum layer and the film. Then apply a certain amount of protective resin on the aluminum film to prevent the aluminum layer from oxidizing and deteriorating. The aluminum-plated film formed by this process is friction-resistant and not easy to deteriorate.
Common quality problems and solutions of vacuum aluminum plating are as follows:
1. Reasons for brown stripes on the surface of the film:
① Low vacuum solution: Clean the aluminum feeding, evaporation device, cooling system, unwinding, winding device and guide roller in the vacuum chamber; check the vacuum system; reduce the ambient humidity.
②Solution to film release of gas: pre-dry the film; extend the vacuum pumping time.
③Solution to excessive aluminum spraying: increase vehicle speed; reduce the current of the evaporation boat; reduce the speed of aluminum feeding.
④Solution to impurities in the evaporation boat: clean the evaporation boat and the heat shielding plate.
⑤Solution to aging of the evaporation boat: replace the evaporation boat.
2. Causes of holes in the film during aluminum plating:
①Solution to too much aluminum in the evaporation boat: reduce the aluminum feeding speed; increase the current of the evaporation boat.
②Solution to short circuit between evaporation boats in the vacuum chamber: eliminate the short circuit.
③Solution to splashing impurities in the vacuum chamber: clean the inner wall of the vacuum chamber, the aluminum feeding evaporation device, the cooling drum, the unwinding, the winding device and the guide rollers.
3. Causes of film stretching during aluminum plating:
①Solution to excessive tension of the substrate: adjust the unwinding and winding tension control system to appropriately reduce the tension.
②Solution to abnormal operation of the cooling system: check the cooling system and eliminate the fault.
③Solution to too high temperature of the evaporation boat: reduce the heating current of the evaporation boat; increase vehicle speed.
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