2D Processing method
2D sheet metal lamination/ Steel Lamination
Sheet steel is coated on conventional flat lamination systems or modified coil coating systems. The substrate can be steel, stainless steel or aluminum. According to the principle “Finish first - Fabricate later”, the coated sheet metal is produced in the first processing step. In the second step, the coated sheet steel is turned into the end product by punching or bending, among other things.
The process is suitable for processing the following products:
Processing Coil-Coating:
In the coil coating process, bonding is ensured by a heat-activated polyester-based adhesive. The sheet to be laminated is exposed to a high thermal load at a temperature of approx. 200 °C for a short time - this varies depending on the cooling process, the sheet thickness and the processing speed.
2D profile sheathing
The process is suitable for the two-dimensional wrapping of profiles and panels for furniture construction. Difficult geometries can be processed using profile wrapping. Processing takes place on a wrapping machine with adhesive application by roller or slot nozzle. Common hot-melt systems are suitable as adhesives. The carrier material can be made of MDF, for example, but can also be made of metal or plastic.
The process is suitable for processing the following products:
Notes on the processing method for RENOLIT ALKORCELL
- Heat shield to prevent unwanted melting of the film, only for the application of adhesive with an application roller (PVC films are not suitable for application with an application roller due to their low softening temperature)
- Wrapping zone with additional hot air blower for a smooth wrapping process at the edges
- Cutting devices to cut the profiles (e.g. with a diagonal circular saw)
Stretching:
When wrapped with hot-melt adhesive (melting temperature: ~ 180°C), the film is thermally stressed and can be stretched. It is important not to exceed a maximum elongation of 2% in order to avoid unwanted shrinkage of the film. The minimum film thickness of 120 my reduces stretching and supports safe processing. Ensure low web tension when wrapping. By releasing the brake on the unwinding, you ensure a correspondingly low web tension during coating.
RENOLIT ALKORCELL is a thermal laminate. It is therefore very important to monitor the expansion during lamination (max. 2%).
Aggregates:
Different applications are possible depending on the equipment and machine settings. Almost every machine has a different design due to the arrangement and equipment of the various units.
- Cleaning unit with rotating brushes for edges and surfaces
- Substrate preheating zone with infrared, radiant heaters or hot air
- Single or double unwinding for narrow-width decorative foils
- Adhesive application via slotted nozzle or application roller on the back of the film
Suitable carrier materials:
The following substrates are particularly suitable for lamination with 2D films from RENOLIT:
Foamed PVC
Plastic profiles
MDF
Tubular chipboard
Solid chipboard
Honeycomb inlay
Tubular chipboard is often used for interior door applications as it offers sound insulation and above-average stability.
2D Production of door leaf, door frame and door edge
Door frame:
For example, RENOLIT ALKORCELL, RENOLIT ALKORFOL and RENOLIT 2D PET Laminate are suitable for coating frames with smooth edges using the folding process or profile wrapping process. Profile wrapping is the method of choice for round frames.
Door leaf:
The most common processing method for the door leaf is flat lamination. Edgebanding is used for angular narrow surfaces, while 2D coating is the most suitable method for round edges.
Door edges:
The edge design refers to the visible shape of the upper and longitudinal door edges. The edge design also refers to the outer edge of the frame. Depending on the desired design of the door and the required resistance, there are square, round and profiled door edges.
Round edges:
The rounded edge creates a soft transition. In addition to the harmonious design, rounded door edges make the frame more stable. This makes the door more robust against knocks and general wear and tear.
Corner edges:
The corner edge stands for the standard of edge shapes. The simple design is timeless and minimalist. However, the right-angled shape of the door edge is more susceptible to damage compared to the round edge, for example due to knocks from objects.
Manufacturing of 2D edge profiles
To produce two-dimensional edge profiles, three different ways of applying edge material to narrow surfaces are presented below. The methods depend in particular on the door construction and the technical coating options on site.
Possible processing methods for 2D edge profiles: Softforming
- Postforming
- Sheathing of door leaves
- Sheathing of panels
Application image: Processing method 2D edge profile
Softforming
In the softforming process, the substrate surface is first surface-coated. The raw profile is then formatted, profiled and ground. Finally, the surface can be coated with the edge material and milled flush. The edge coating of the upper front edge is carried out in a separate work step. Either edge banding machines (with edgebanding material) or hot stamping machines (with “transfer” or “hot stamping foils”) are suitable for this.
Softforming-Profiles
Roof profile
Barrel profile
Insert profile-U
S-profile
Insert profile-L
Application example for direct postforming
Direct postforming is a coating process in which the surface, profile and edge are coated seamlessly with one material.
Advantages:
- Continuous surface material
- No butt joint
- No possibly different aging
Application example: Direct postforming
After the coating process, the edge profile is milled in such a way that a thin carrier layer of the board (MDF or chipboard) remains underneath the film. This gives the film more stability, the bond between the film and the substrate layer is folded over using deflection rollers and glued with PUR hotmelt adhesive. This means that there are no gaps in the visible area. The edge coating of the upper front edge is carried out in a separate work step. Either edge banding machines (with edge material) or hot stamping machines (with ‘transfer’ or ‘hot stamping foils’) are suitable for this.
Sheathing of panels/door leaves
No edge material is required when wrapping panels and door leaves. However, this technique requires the use of substrate material with the highest possible material density or a fine surface structure (e.g. MDF).
