Fluorex Paintfilms - Soliant Introduction

1 Fluorex Paintfilm Laminates Processing Guide Note: The information contained within this document is considered recommended guidelines only, and intended to familiarize our customers with Fluorex products. Processing parameters for any thermoformed or injection molded part is dependent on the design configuration and materials used in the process. In order to determine the best possible processing conditions, each part will require testing prior to implementation into any production environment For more information, please visit our website: Or contact your local AkzoNobel Specialty Finishes office. Fluorex Paintfilms GTS-9/13 2 Table of contents Materials: Page 1) Description 3 2) Typical properties 3 3) Handling and Storage 4 Thermoforming process: 1) Equipment 5 2) Thermoform Mold 6 3) Trimming 7 4) Appliqu (insert) handling recommendations 7 5) Thermoform process conditions 8 6) Trouble shooting (thermoforming) 8+ Injection molding process: 1) Equipment & Process parameters 10 2) Runners and Gates 11 3) Finished part handling 12 4) Trouble shooting (Injection molding) 13 Design considerations 14 Glossary 14 GTS-9/13 3 Materials 1) Description.

2 Fluorex Paintfilm laminates are a thermoplastic clearcoat / colorcoat product, with an option for a decorative print on top or in between the clear- and colorcoat. Topcoats are mechanically and thermally bonded to a thermoplastic substrate, typically ABS or TPO. This material is typically supplied in roll form and is available in widths varying from 300 mm (12 inch) up to 1200 mm (48 inch). The thickness of the laminate is dependent on the type of product selected. Most common grades used for thermoforming and insert injection molding have a total thickness of (10 mil to 30 mil) +/-10%. Note: Fluorex T/HR, A/HR and Clear/HR are materials that are not suitable for pre-forming and insert molding. These products are normally used as: A) Capping film / top-layer material in an extrusion lamination process.

3 B) In Mold Decoration film (transfer molding) Technical details of Fluorex T/HR, A/HR and Clear/HR will not be discussed in this processing guide. Information on Extrusion lamination can be found in Technical Bulletin #004: Extrusion Lamination Information on IMD (insert molding without preforming the film) can be found in Technical Bulletin #005: Fluorex in IMD process 2) Typical properties: All Fluorex products which are laminated to a thermoplastic carrier (ABS*, TPO**, PC) have the tendency to shrink after processing. Typical shrinkage rates are listed below: Material Typical shrinkage (%) Fluorex on PC substrates Fluorex on ABS substrates Fluorex on TPO substrates Shrinkage rates may vary, depending upon part geometry and thermoforming conditions.

4 The temperature of web and the thermoforming mold has a definite influence on shrinkage rates. It is essential to measure shrinkage on all applications during the prototype phase, using consistent processing conditions. Maximum shrinkage will be reached after 48 Hrs. The typical use for Fluorex material with a thermoplastic carrier is forming in a thermoforming process followed by an injection molding process (insert injection molding or overmolding). The Fluorex 30xx materials are generally used for relatively larger appliqu s that require handling stability. GTS-9/13 4* ABS backing material is an extruded, high surface quality ABS film. The ABS backing is compatible with ABS resin and most blends of PC/ABS and PC/PET injection molding resins.

5 ** TPO backing material is an extruded film blend or Copolymer of PE, PP, impact modifier and filler. This blend offers the ideal combination of high surface quality, high impact, low thermal expansion and controllable shrinkage. The TPO backing is compatible with PP, EPDM and TPO injection molding resins, including most blends of these products. Gloss: Fluorex products allow the customer the flexibility of choosing a wide variety of gloss levels from Class A, high-gloss to matte and even soft touch finishes. Note: The high gloss product can be supplied with a thermoformable premask that is designed to prevent change in gloss when Paintfilm is thermoformed. This premask also protects the high gloss finish during subsequent operations (trimming, injection molding, shipping, installation, etc.)

6 And can eliminate the need for a highly polished tool. The patented Fluorex basecoat/clearcoat construction consists of a Polyvinylidene Fluoride - Acrylic alloy. This composition provides the optimum balance of properties such as chemical, scratch & mar, and stone chipping resistance as well as excellent resistance to fading or yellowing under UV exposure. Automotive grade pigments, metal flakes, and micas are added to the basecoat for matching product color to OEM specifications. In addition to straight shades and metallics, difficult to match pearlescent and tri-coat colors currently used in high end automotive finishes can be replicated as well. Other Properties: Fluorex In-mold Paintfilm is a custom color matched durable film that meets the demanding specifications of the automotive and consumer electronic industries.

7 The fluoropolymer clear coat of Fluorex Paintfilms offer comparable weathering, acid rain and chemical resistance to that of traditional spray-painted surfaces. Fluorex Paintfilms form a far superior bond to the part surface than sprayed paint, which results in outstanding chip resistance. Note: For more information on these and other properties, please refer to the individual product data sheets, which can be found on our website at 3) Handling and Storage: Our Paintfilm laminates use only high quality plastic backing substrates. These materials are carefully selected for their thermoformability and high surface quality characteristics. Material ready for shipment is slit to the required width and length and then coiled onto a standard 6 (152 mm) inside diameter plastic core.

8 Non-hygroscopic substrates such as TPO are wrapped in Polyethylene liners, while hygroscopic materials like ABS are wrapped in moisture resistant PE/Alu liners including a unit of desiccant silica gel. Rolls are shipped in cardboard boxes, suspended in plastic supports to prevent damage. All Fluorex products should be handled with care and stored on pallets during transport and handling to assure the packaging integrity. GTS-9/13 5 Storage conditions: Fluorex materials will experience their longest useful life when stored in a temperature and humidity controlled environment: <22 C and minimal humidity. Boxes containing rolls of Fluorex should be stored in a horizontal position suspended by their cores.

9 (Storage in the vertical position can result in cold flow of the thermoplastic backing resins). This material should not be stored outdoors, in places of high humidity or where extreme temperatures can be attained. Temperatures below the freezing point and over 95 F (35 C) should be avoided. When using hygroscopic substrate materials (such as ABS and PC), rolls should be kept wrapped in a sealed moisture vapor barrier with desiccant inside. After 5 to 6 months of storage, rolls may need to be unwrapped and dried prior to processing to avoid defects due to moisture absorption. Drying conditions: 72+ hours in a circulation oven @ 60 C. Thermoforming Process 1) Equipment: Various types of thermoforming equipment can be used to process Fluorex materials.

10 A clean environment is essential to produce high quality appliqu s. Roll fed thermoforming equipment with vacuum and pressure assist is generally preferred. This assures continuity and optimal use of the product. In this process the roll Fluorex is unwound and indexed by a transport system through heating zone(s), over the forming platen and into the trimming station(s). Thermoforming equipment should be placed in a draft free area (preferably temperature and humidity controlled), to assure a consistent heating profile. Since laminate temperature is one of the most critical process parameters, it is important to have adequate control over the heating step. Thermoforming machines should have both top and bottom heating.