1. Introduction Lamination Cast Film Coating Calendering 1 2 3 4 5 Outline

3. LAMINATION What ? What ? Lamination is a process of permanently joining two or more prefabricated sheet materials. Why? Why? To combine the performance features of two or more different materials. Barrier properties, Surface and Mechanical properties.

4. Apply and Meter: The material is applied with adhesive (unmeasured) and then squeezed to predetermined thickness. Advantages: 1. Easy Change over 1. Easy Change over 2. Low Investment 2. Low Investment Disadvantages: Disadvantages: 1. Unevenness 1. Unevenness 2. Slow speed 2. Slow speed

5. Meter and Apply: The material is applied with predetermined adhesive quantity and then squeezed. Advantages: 1. Uniformity of the substrate 2. High speed 2. High speed Disadvantages: Disadvantages: 1. High cost. 2. Change over time is more. 2. Change over time is more.

6. Saturate and Remove: The material is impregnated in the adhesive bath and the excessive quantity are removed. Advantages: 1. Easy change over 1. Easy change over 2. Low Investment 2. Low Investment Disadvantages: Disadvantages: 1. Slow speed 1. Slow speed 2. Down time, Breaks 2. Down time, Breaks

7. APPLICATIONS: Automotive Industry : Head linings, Hat racks, Door side panels, Linings for floor components, Sound insulation and vibration damping. Construction Industry : Laminates of glass fiber nonwovens and poly urethane films are used as insulating panel against heat or cold in light construction. Floor Coverings: Laminated nonwovens are used as secondary backing providing resilience and insulating properties.

8. The cast film extrusion process is gaining increased popularity and enjoying sustained growth worldwide. New lines are being installed in a significant number and the market segments penetrated by this technology are on the rise. This article identifies the main components of a cast extrusion line and presents the fundamental aspects that require consideration when approaching cast film technology.

9. Cast film Lines

10. Cast film material

11. Cast film Machine

12. Applications WrapProtection

14. A coating is a covering that is applied to the surface of an object, usually referred to as the substrate. The purpose of applying the coating may be decorative, functional, or both.

15. Types of coating Dip coating Extrusion coating

16. is the coating of a molten web of synthetic resin onto a substrate material. It is a versatile coating technique used for the economic application of various plastics, notably polyethylene, onto paperboard, corrugated fiberboard, paper, aluminum foils, cellulose, Non–wovens, or plastic films.

17. Extrusion coating process

18. 1- Extrusion Coating and Lamination Resins. 2- Provide barrier against moisture, grease, gas and aroma.

19. Dip coating is the simple process of using a molten coating material to provide a decorative or protective plastic covering to a wide variety of objects. Used by industries such as consumer, automotive and electronics, dip coating involves dipping an object into a viscous material which will cling to the object and harden, leaving a film of plastic on the surface.

20. Dip coating

21. 1- Hot dip coating of plastisol is a common method of applying a protective, decorative, or functional plastic vinyl coating on a variety of metal parts. 2- Typical applications provide a protective layer against sharp or rough materials, a protective plastic layer to prevent corrosion, or just a beautiful and soft coating to enhance the product's appearance. 3- It is much more cost effective to do a one step dip to coat a product, for instance a tool grip, than it is to injection mold a sleeve and then apply it to the handle. The coated grip is softer, has no seam lines, and adheres better to the product to be coated

22. 1- Part Cleaning 2- Part Priming 3- Part Dipping 4- Fusion (Curing) plastic polymer 5- cooling the Coated Part 6- from the conveyors and readied for packing and shipment.

24. Hand tools Toys Medical Instruments Electrical Equipment Plumbing Fittings

25. Hand tools: Toys Medical Instruments Electrical Equipment Plumbing Fittings Applications of dip coating Applications of dip coating

26. 1- Insulates against heat, cold, stress and electrical currents. 2- Dip coating provides a protective shield that resists corrosion. 3- Alternative colors and finishes (glossy and matt) can be created easily and economically.

27. Involves rolling out a mass of premixed plastics material between large rollers to form a continuous and accurately sized film. The process begins with the ingredients being blended and fluxed in a mixing mill at approx.100°C. Nip rollers control the thickness of the sheet material can be gradually reduced in thickness. Rolls of semi-rigid PVC which will be used to manufacture transparent A4 folder 'pockets'.

28. Calendering Lines

29. The 4 types of Calendering lines

30. Calendering material

31. The best quality sheets of plastic today are produced by calenders; in fact, the only process that competes with the calender in sheet forming is extruding. The calender also is very good at handling polymers that are heat sensitive as it causes very little thermal degration. Another advantage to calendering is that it is good at mixing polymers that contain high amounts of solid additives that don't get blended or fluxed in very well. This is true because compared to extrusion the calender produces a large rate of melt for the amount of mechanical energy that is put in.

32. Although the calendering process produces a better product than the extruding process there are a couple of disadvantages. One disadvantage is that the process is more expensive to perform which is a major deterrent for many companies. The calendering process also is not as good at too high of gauges or too low of gauges. If the thickness is below 0.006 inches then there is a tendency for pinholes and voids to appear in the sheets. If the thickness is greater than about 0.06 inches though there is a risk of air entrapment in the sheet. Any desired thickness within that range though would turn out much better using a calender process.

33. 1- floor tile 2- continuous flooring 3- rainwear 4- shower curtains 5- table covers 6- pressure-sensitive tape 7-automotive and furniture upholstery 8- wall coverings 9- luminous ceilings 10- signs and displays