Failure Analysis in the Compound Process of Aluminum Foil and Aluminized Film

Currently, aluminum foils and aluminized films are the most frequently used and fashionable substrates, but aluminum foils and aluminized films may not be noticed in the process of compounding. Quality problems may occur. For example, the most common composite products are spotted and white. Points and other quality issues. This article will focus on the failures and countermeasures in the composite process of aluminum foil and aluminized films.

spot

The aluminized composite film produces a noticeable white or grey spot. These spots are most common in the full-print printing ink composite process. The main reasons are threefold:

1. The quality of the aluminized film itself is poor, the coating is easily peeled off, and the aluminized film and the calendered film are not even. In particular, when the adhesive is coated, the unevenness of flow occurs. After the compounding, white dots that are dense or irregular in size appear more easily. Inks and adhesives have different levels of adhesion on the surface. The adhesion between the ink layer and the coating at the spots where the spots are generated is low (due to the uneven distribution of the ink or adhesive), resulting in poor adhesion between the layers; Plating at the place has obviously shifted and the tightness between the layers is good. Reflected by the aluminum layer reflective intensity, the formation of white spots or gray spots, the degree of speckle depth and ink hiding power and the amount of sizing, especially glue leveling are very much related. Good hiding power, light spots; good leveling and uniform coating, less white spots. On the contrary, there are many spots and serious white spots.

2. The ink itself has poor tightness and poor hiding power. After the printing film is coated, the ink layer is infiltrated with the acetate alcohol in the adhesive, and some of it is dissolved. After the compounding, the ink layer and the adhesive layer are easily infiltrated and destroyed by the solvent of the adhesive system, resulting in different shades and causing different color shades. , it forms a so-called spot.

3. Poor adhesive quality. This adhesive has a poor affinity for the aluminized layer, especially the uneven adhesive in the OPP printing film and BOPP printing film and the aluminized film compound, this glue performance is more obvious. This is mainly due to the high surface tension of the adhesive, poor coating performance, uneven coating of the glue, and “spotting”. At the same time, this glue generally has high initial tack, poor solvent release, and due to the influence of residual solvents after aging, the strength is not as good as the initial tack. After the printing film is compounded, the ink layer is infiltrated with the residual solvent, and there is also the possibility of spotting. The above phenomenon will be more obvious when such adhesives are used in high-speed composites on rolls with more than 150 lines. If the adhesive coating fails to produce slight solubility with the ink of the printing ink, no white spots are visible on the surface, but after the composite process, the adhesiveness of the adhesive layer to the ink layer or even the printing film layer cannot reach the actual requirements of the packaged product. Easily stripped.

In general, there are many “speckle” phenomena caused by the above three reasons, but we can use the following methods to eliminate this phenomenon:

1. The use of ink with better hiding power is the most fundamental method to eliminate the phenomenon of spots caused by the former species. It is also possible to dip the deep-drawing screen roller to increase the thickness of the ink layer, but this increases the cost.
2. The use of a suitable adhesive for aluminized films is an effective way to eliminate the speckle phenomenon caused by the third reason. The special adhesive for the aluminized film is moderate in molecular weight and uniform, and the initial adhesive force is not very high, but the coating performance is excellent, the solvent release property is good, and the peel strength is good after aging. In addition, if you do not have a good aluminum foil adhesive, you can use a deeper network roller, while reducing the operating concentration, slow down the speed, you can also reduce or solve the "spot" phenomenon.

3. If it is caused by pigments or fillers in the ink, there are often spots in the three cases: (1) When the titanium dioxide, etc., are not equal in size and particle size, and one of the pigments is in a flocculation state, but the same density, Spots will appear; (2) Titanium dioxide and other particles of equal size, but the density is different, there will be spots; (3) titanium dioxide and other particles are not equal in size, but the density is not the same, the same will appear spots. These three types of failures are most likely to occur after the addition of silica to the “active particles” resulting from the flocculation or ink grinding for too long. For this phenomenon, as far as possible, all dry powders should be mixed before being put into dispersion, and the amount of white carbon black can also be reduced, or dispersant or antistatic agent can be increased, or the grinding time can be shortened (mostly due to this failure. 静坏窨痰 窨痰 竺婊 竺婊 嫔 嫔 嫔 嫔 共 共 共 共 共 5 铡 (8) 涞 涞            一 一 一 一 一 一 一 一 一 一 一 一 一 一 一 一 一 一 一 一 一 一 一It is best to add "CHY-1" type printing aid to eliminate spots.

White dot

In addition to the white point of the aluminized composite film, there are also obvious white spots on other composite films. Such white spots can be randomly distributed and have uneven sizes. One is when there is a machine, but it basically disappears after aging; the other is when it is off machine and does not disappear after aging. The latter is the biggest problem affecting performance. Such spots are most likely to appear in printed effects with white or light yellow bottoms. In general, as long as such a white point occurs, it is generally full version (except for equipment reasons), but the difference between white and light yellow hiding power is easy to see. There are many reasons for the phenomenon of white spots. There are three main reasons:

1. The ink has a large particle size or a narrow particle size distribution, and the white ink generally has a large particle size effect. The ethyl ester in the adhesive is a good solvent for the ink, and the results of infiltration of ink particles with different particle sizes are different. The color change after heating or compounding in an oven may cause a difference, and it seems to produce a “white point”. In this kind of situation, when the machine is down, the white point phenomenon will be lessened and may disappear after curing. When printing, it is best to add a 1.5-3% M-27 coupling agent, such as Tian Yang Chemical Factory, to increase the tightness of the pigment packing in the ink system to resist the large area caused by the solvent infiltration and destruction in the adhesive system. White spots or spots.

2. The surface tension of the adhesive is high, and the effect of wet spreading on the aluminized film is poor. This is the "white spot phenomenon" of the current aluminized film, and it is also the main reason for the occurrence of spots on other composite films. The effect of the adhesive coating is not good. After the printing layer is covered, the color of the different parts will change, resulting in the same effect as before, and sometimes large spots will be produced.

3. Equipment process reasons. On the one hand, the reason for this is that the workers are not aware of the special nature of the aluminized film composite. The aluminized film compound has its unique place. On the other hand, the pressure on both sides of the equipment during the sizing process is inconsistent, even in the system itself such as drying and coating. The problem does not guarantee adequate uniform coating of the adhesive or sufficient volatilization of the ethyl ester. There are other reasons, such as full-bottom printing network roller roller mesh is too shallow, reducing the hiding power of ink and so on.

Take the following measures to eliminate "white spots":

1. Different batches of inks increase the fineness detection index and are strictly controlled. In particular, the size and fineness of full-bottom inks are not used outside the standard range.

2. Aluminized film adhesives are used. The special adhesive for aluminized films has a lower surface tension, and the effect of coating and spreading on the surface of the aluminized layer is significantly better than that of a general-purpose adhesive. The use of aluminized film glue is very easy to control the leveling of the glue and has a better coating state. From the adhesive coating state alone, the use of aluminized adhesive can eliminate white point phenomenon.

3. The viscosity of the glue has a certain matching relationship with the number of roller lines of the cable. Exceeding the matching range too much will destroy the coating state of the glue, causing the occurrence of “white spots” and more serious failures, but it seems to be mainly on the aluminized film. The creation of "white spots" is even more of a concern.

4. Aluminum film coating method. The commonly used coating process is a printing film (protective layer) coating, where a special coating method is used to avoid the problem of inhomogeneous penetration of ethyl ester to the ink layer, but this process has its very big limitations. First of all, it is limited to the compounding of VM PET, and second, it will sacrifice a certain peel strength.

5. The manufacturer must adhere to the regular cleaning system of the coating roller and grasp the correct cleaning method of the coating roller. In the production of full white or yellow line printing film, pay attention to two points: First, before the production of the blade, the coating roll, flat roll and other thorough cleaning; Second, for the old domestic dry machine, the speed ratio than normal Slower speed to ensure the drying effect.

Point

Printed on the aluminized film often due to the foam in the ink pinhole (blank point / pit) failure, the general exclusion method: First, tighten the composite roller; second is to increase the amount of coating glue; third is to add defoamer Simethicone oil; Fourth, try to use a straight blade, and increase the scraper blade 1-2mm, or use a soft blade (such as steel tape instead), and the blade angle is adjusted to not less than 45 ° angle; five is Add a piece of rubber on the back of the scraper, which can effectively scrape off the spots caused by the poor dispersion or the oxidized crust in the printing and graphic ink system; add the white carbon black into the printing ink to promote printing. The ink ink film is thickened to increase the hiding power of the white ink ink film; the seventh is to reprint again to increase the thickness of the ink film; the eighth is to select the deep gravure printing to increase the transfer rate of the ink; 9 is to put a stirrer in the ink fountain. The device ensures the uniformity of the printing ink in the transfer process. Tenth, it replaces the printing ink with high viscosity and antistatic printing or slows down the printing speed, and strives to eliminate the problems of pitting, pinholes, spots and white spots.
In actual production, only high-efficiency additives and new materials are used to make up for the deficiencies in the aluminized composite printing products and improve the quality of the packaging printing process.

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