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        2. Aluminum Coating Process

          Jun 20, 2024 Leave a message

          The aluminum plating process of plastic film generally adopts direct plating method, that is, the aluminum layer is directly plated on the surface of the substrate film. BOPET and BOPA film substrates do not need surface treatment before aluminum plating, and can be directly evaporated. For non-polar plastic films such as BOPP, CPP, and PE, the surface of the film needs to be corona treated or coated with an adhesive layer before evaporation to make its surface tension reach 38-42 dynes/cm or have good adhesion. During evaporation, place the roll film in a vacuum chamber and close the vacuum chamber to evacuate. When the vacuum degree reaches a certain level (above 4×10-4mba), heat the evaporation boat to 1300℃~1400℃, and then continuously feed aluminum wire with a purity of 99.9% to the evaporation boat. Adjust the unwinding speed, winding speed, wire feeding speed and evaporation amount, open the cooling source, and make the aluminum wire melt and evaporate continuously on the evaporation boat, so that a bright aluminum layer is formed on the moving film surface after cooling, which is the aluminum-plated film.
          Principle of vacuum evaporation
          The film substrate (cylindrical) to be plated is placed in a vacuum evaporation machine, and a vacuum pump is used to evacuate the film to a vacuum degree of 1.3×10-2~1.3×10-3Pa. The crucible is heated to melt the high-purity aluminum wire at a temperature of 1200℃~1400℃ and evaporate into gaseous aluminum. The gaseous aluminum particles are deposited on the surface of the moving film substrate and are cooled and reduced to form a continuous and bright metal aluminum layer. The thickness of the aluminum coating layer is controlled by controlling the evaporation rate of the metal aluminum, the moving speed of the film substrate, and the vacuum degree of the coating chamber. Generally, the thickness of the aluminum coating layer is 25~500nm, and the width of the aluminum film is 800mm~2000mm.
          Evaporation method: There are two methods for evaporating aluminum on the surface of the substrate: direct evaporation method and transfer method.
          (1) Direct evaporation method. The substrate to be plated directly passes through the vacuum coating machine, and the metal aluminum is evaporated on the surface of the substrate to form an aluminum film. The direct evaporation method has high requirements for the substrate, especially to form a shiny metal film, the substrate must have good surface smoothness. If the surface of the paper is rough, the direct evaporation method should be used, and the surface must be coated before aluminum plating. In addition, the volatile matter of the substrate should be less during the evaporation process. Therefore, the direct evaporation method has great limitations on the substrate. It is mainly suitable for evaporation of plastic films and can also be used for evaporation of paper, but the quality requirements of paper are high and there are certain limits on the quantity of paper.
          (2) Transfer method. It is to transfer the metal aluminum layer to the surface of the substrate with the help of a carrier film (vacuum aluminum film) to form an aluminum film. The transfer method is a new process developed on the basis of the direct evaporation method. It overcomes the limitations of the direct evaporation method on the substrate requirements. It is especially suitable for aluminum plating on various papers and paperboards, and can also be used for aluminum plating of plastic films. Foreign countries have applied the transfer method to aluminum-plated products on substrates such as cloth, fiber, and leather. my country mainly uses the transfer method to produce aluminum-plated paper. [1]
          Aluminum-coated film production process:
          Substrate unwinding → vacuuming → heating evaporation boat → feeding aluminum wire → evaporation → cooling → thickness measurement → flattening → winding

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