Production process
Ingredients and mixing: Put polyvinyl chloride (PVC) resin and plasticizers, stabilizers, lubricants, pigments and other additives into a mixer in a certain proportion and mix them thoroughly. Plasticizers can reduce the melting temperature and viscosity of PVC resin and improve processing performance; stabilizers can inhibit the thermal oxidation degradation of PVC resin during processing; lubricants help reduce friction and make the material smoother during processing; pigments are used to give the product the desired color.
Melt extrusion: The mixed material is fed into the extruder, and the material is gradually heated to a molten state in the barrel of the extruder through heating and the rotation of the screw, becoming a uniform melt with a certain fluidity. This process requires precise control of temperature and screw speed to ensure that the material is fully melted and does not decompose.
Calendering: After the molten PVC material is extruded from the extruder, it enters the calender. The calender is composed of multiple rollers. The material is squeezed and stretched between the rollers and pressed into a thin sheet with a certain thickness and width, which is the base material of the PVC Flex Banner. During the calendering process, the temperature, pressure and speed of the rollers must be strictly controlled to ensure the thickness uniformity, surface flatness and physical properties of the base material.
Laminating the base fabric (if any): For some PVC Flex Banners that need to enhance strength and stability, a layer of base fabric, such as high-strength polyester mesh, will be laminated on the calendered PVC sheet. Usually, thermal lamination or gluing lamination is used to firmly bond the PVC to the base fabric to improve the tensile strength and tear resistance of the product.
Surface treatment: In order to improve the performance and aesthetics of the PVC Flex Banner, it will be surface treated. Common treatment methods include coating and lamination. Coating is to apply a special coating on the surface of PVC, such as a coating with waterproof, anti-fouling, anti-ultraviolet and other functions; lamination is to cover the surface of PVC with a protective film, such as a transparent PVC film or a film of other materials, which can enhance the wear resistance and weather resistance of the product.
Printing: According to the customer's design requirements, use inkjet printing, screen printing and other technologies to print patterns and texts on the surface of PVC Flex Banner. During the printing process, it is necessary to accurately control the color of the ink, the drying speed and other parameters to ensure the printing quality, make the pattern clear, colorful and have strong adhesion.
Cutting and molding: After printing, according to the size and shape requirements of the product, use a cutting machine to cut the PVC Flex Banner into the required specifications. The cutting process must ensure accuracy to avoid problems such as dimensional deviation and edge burrs.
Inspection and packaging: Conduct a comprehensive inspection of the produced PVC Flex Banner to check whether the product's appearance quality, dimensional accuracy, physical properties, etc. meet the standard requirements. Qualified products are packaged, usually in roll packaging or folding packaging for transportation and storage.
Related technologies
Intelligent control technology: During the production process, an intelligent control system is used to monitor and adjust production parameters such as temperature, pressure, and speed in real time to ensure that each production link is in the best state, improve production efficiency and product quality stability, and reduce human operation errors.
Environmentally friendly production technology: With the improvement of environmental protection requirements, PVC Flex Banner manufacturers continue to optimize production processes, use environmentally friendly raw materials and additives, and reduce the emission of harmful substances. For example, environmentally friendly stabilizers such as lead-free and cadmium-free are used, and water-based inks are used for printing to achieve green production processes.
New material application technology: Research and develop new materials to improve the performance of PVC Flex Banner. For example, adding nanomaterials, functional additives, etc. can improve the heat resistance, cold resistance, and antibacterial properties of the product; developing new base fabric materials can further enhance the strength and stability of the product.
Printing technology innovation: Continuously introduce and improve printing technology, such as using high-precision inkjet printing equipment and advanced printing software to improve printing resolution and color reproduction, and achieve more complex and exquisite pattern printing. At the same time, new printing processes are developed, such as 3D printing, fluorescent printing, etc., to add unique visual effects to the products.
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