Polyvinyl chloride (PVC) is a polymeric material that is widely used in various areas of promotional products, in the process of repair and construction work, in interior design.
Success story
The rich 30-year history of PVC material in the field of thermoplastics is striking in its uniqueness. Due to its excellent properties and characteristics, foamed PVC has a huge variety of applications in all areas of the daily life of a modern person. The starting materials for the production of polyvinyl chloride are raw materials such as coal, oil and gas. Polymerization of the vinyl chloride intermediate produces the final PVC material, which is composed of carbon dioxide, hydrogen and chlorine molecules.
Numerous developments in the field of production, improvement of formulations and processing methods have shown that, due to its unique molecular structure, the substance occupies a special place among other types of thermoplastics.
Foamed PVC has a lot of positive qualities:durability of operation, resistance to temperature extremes, mechanical stress, a variety of processing methods and excellent chemical resistance. Excellent impact resistance and the possibility of outdoor use is achieved through the use of various additives. PVC foam sheet is the most common PVC product.
The first Russian production of PVC plastic was introduced by United Extrusion under the UNEXT brand. The use of modern high-tech equipment allows us to produce products that meet all international standards. Thanks to the use of the best raw materials and a unique recipe, UNEXT PVC foam is no different from its European counterparts.
Types of sheet plastic
Since the introduction of sheet material into the market, PVC foam has rapidly developed into a versatile product. A variety of types of PVC sheet with special properties allows the material to be used to implement ideas in a wide variety of areas.
There are several types of the most common hard PVC sheet:
- Inert PVC Foam Sheet - manufactured using the latest technology. As a result, the internal structure is uniform and porous, and the outer surface on both sides is smooth and glossy;
- PVC Loose Foam Sheet is a lightweight plastic made of rigid PVC, characterized by a silky surface and fineporous structure;
- compact sheet - has good impact resistance and high stability;
- compact transparent PVC sheet is a transparent plastic with excellent light transmission and impact resistance;
- wavy transparent sheet - designed specifically for roofing, characterized by low flammability;
- PVC Composite Sheet - The inside is free foam plastic and the outside is a double-sided aluminum coating.
The variety of types and high technical reliability of PVC sheets make plastic universal for various applications: interior decoration of buildings, construction, erection of advertising and information stands, interior design of shops and trading floors, mechanical engineering, etc.
PVC Foam General Specifications
- The material does not absorb water and moisture from the air, so it does not swell and, as a result, does not deform throughout the entire service life. Even when in water for a long time, the appearance of the plastic and its performance does not change.
- One of the main advantages of PVC sheet is its fire safety - plastic belongs to the group of flame-retardant materials that do not support combustion in air.
- PVC foam has excellent lightfastness.
- The material is used to create elements of complex shape using thermo, pneumatic and vacuum forming methods.
- Plastic is resistant to most common chemicalsproducts: household detergents and disinfectants, solutions of acids and alkalis.
- PVC is an environmentally friendly material that does not contain heavy metals and does not have a negative impact on human he alth and the environment.
- The material is easily machined and hand-crafted with conventional tools: easy to cut, drill, saw, bend, glue, nail, screw and rivet.
- Plastic surface is ideal for self-adhesive and laminating films, as well as for screen printing, screen printing inks and varnishes.
Processing methods
PVC foam sheet is easily subjected to any processing and bonding method. Due to its mechanical features, plastic does not require the use of complex and expensive equipment. PVC sheets can be processed with conventional tools that are used when working with wood or metal.
PVC sawing
Foamed PVC sheet can be sawn manually with a circular saw, bandsaw and jigsaw. The material can be sawn with a hand saw designed for woodworking. Metal saws can become clogged due to the close spacing of the teeth. Optimal sawing parameters:
- speed up to 300 m/min;
- feed 30 m/min.
Specialists recommend the following indicators of tooth angles: α=5 - 10° - front angle, b=10 - 20° - back, with a tooth pitch of 5 to 10 mm.
Drilling
Foamed PVC is drilled with conventional drills designed for working with metal. The most optimal effect is achieved at a speed of 50 to 300 rpm and a feed of 3.5 to 6 m/min. Angles are recommended to be used with the following values:
- φ=100 - 110° - vertex angle;
- β=30° - elevation angle;
- α=0-5 0 - rake angle.
Milling
Standard universal vertical and horizontal milling machines can be used to process PVC plastic. To prevent damage to the surface of the material, plastic or wooden gaskets are used during fixation. Optimum operating mode:
- cutting speed no more than 900 m/min;
- material feed 0.3 - 0.6 m/min;
- rake angle α=5 - 20°;
- relief angle γ=10-25°.
Processing the edge of the sheet
PVC foamed sheet requires finishing edges. For these purposes, you can use a planer, sandpaper or other equipment used for filing the edges of wood or plastic. If the material is subjected to constant dynamic loads, irregularities can lead to fractures or cracks. A PVC sheet with a thickness of no more than 3 mm can be cut with an ordinary knife.
PVC Plastic Stamping
Punching efficiency depends on several factors:
- sheet thickness - sheets up to 3mm thick can be stamped easily. If special equipment is used andcorrect methods, it is possible to stamp simple shapes from PVC with a thickness of 4 to 6 mm. Keep in mind that the edges of the sheet will be slightly rounded;
- sheet temperature - with a slight heating of the material, the quality of stamping improves;
- stamping equipment - suitable for punching cardboard and other foam materials;
- blade angle - a prerequisite for high-quality stamping is the location of the blades at an angle of 30 °.
Hot bending
For these purposes, any standard thermoplastic bending equipment is used. Accurate bending depends on uniform temperature distribution and the preliminary definition of a zone of constant heating. The most optimal temperature level is from 115 to 130 °C. If the temperature is above the specified maximum, there is a high probability of cracking and splitting of the PVC honeycomb structure. Most often this happens when bending thicker sheets. In case of insufficient heating, the material will be subjected to strong stress and possibly return to its original state.
When bending foam materials, single-sided heating is only successful up to a certain point, so the bending radius may be visually unsatisfactory. In this case, a V-shaped incision is applied to the inside of the sheet. A prerequisite is the fixation of the resulting product until the material has completely cooled down.
PVC sheet bonding
PVC foamed roll can be glued with various types of adhesive. If you need to glue the sheets betweenyou can use solvent glue for cold welding or reactive (secondary) glue. When bonding non-porous and non-absorbent materials, the following adhesives are suitable:
- solvent contact - applied to both surfaces in the ratio of 150 g per 1 m22;
- two-component polyurethane - only one surface is coated.
PVC bonding to porous and absorbent materials is done with water dispersion adhesive or two-component polyurethane adhesive.
Specialists recommend testing on a case-by-case basis, taking into account factors that can affect bonding performance: resistance to weather and chemicals, elasticity of the adhesive line.
PVC foam welding
PVC sheets can be bonded with hot air. During the welding process, certain criteria must be observed: the preparation of the weld and the use of the correct temperature. The main thing to pay attention to is to ensure uniform heating, while avoiding local overheating. A standard welding rod can be used to process PVC foam, which should be preheated to 70 - 80 °C.
Main operating parameters:
- The edges of PVC sheet seams should be beveled 60°;
- optimum welding temperature 280 - 290 °C;
- You must use the high-speed welding nozzle (3.5 m/min) during operation.
Thermoforming
PVC foam can be stretched or bent after being heated to a certain temperature. However, due to the fact that the material is a two-phase system, half of the volume of which is occupied by the air inside, some restrictions must be observed. For processing sheets, uniform double-sided heating is recommended. The material should be molded after it becomes elastic. Before thermal exposure, the protective film must be removed from the PVC sheets.
Printing and varnishing
Due to its structure, PVC foam surface is ideal for screen printing and varnishing. For these purposes, special vinyl-acrylic dyes are suitable. Before printing and varnishing, the surface of the sheets is degreased by wiping with alcohol.
PVC foam applications
Due to the high rates of sound and heat insulation and moisture resistance, PVC profiles have been used in window and door production for many years, and serve as a finish for balconies and loggias. Transparent and corrugated PVC sheets are used in the field of roofing and glass substitutes.
PVC profile differs from other materials in its reliability, durability, unpretentiousness in operation.
Continuous improvement in processing methods and manufacturing techniques allows manufacturers to discover new applications for PVC products. PVC foam mat is used as an anti-slip floor covering in the bathroom. Hehas a soft texture and does not absorb moisture.
Excellent for outdoor use PVC foam sheet. The price of this material is much lower than other types of thermoplastic. It is suitable for advertising or as a display. The plastic sheet has good weather and UV resistance.
PVC foam, which has a competitive price, is widely used in advertising, construction and industry. It is lightweight and durable material, with which you can bring any design and color solutions to life.
Building materials manufacturers offer a wide range of PVC products. All of it is distinguished by a variety of colors, sheet thickness, properties. The price of one sheet of 2x3 m varies from 1,500 rubles to 4,500 thousand (depending on the manufacturer and other characteristics).
