What happens in the lamination cycle and when?

Transcription

1 What happens in the lamination cycle and when? By Bill Crawford Waytek Corporation ICMA Workshop October 19, 2009

2 Three variables in card lamination Heat Pressure Time

3 The card lamination cycle 160 Temperature in the book Transfer Temperature of the laminate (?C) Time (min) Temperature in layer 1 and 10 Temperature in layer 5 and 6 Used with permission Dick Crowe Burkle North America

4 The card lamination cycle Temperature [ C] Pressure [Bar] Time [mins] Pressure Temperature Used with permission Barry Cowles Ineos Films

5 Questions When do inks discolor? When do PVC corestocks distort? When do overlays clarify? When do adhesives turn yellow? When do split cores seal?

6 Test Methodology

7 Lamination Defects

8 30 mil split core copolymer card F What happens to each layer during heating?

9 Card construction graphic legend White: The raw material s form at room temperature no physical changes have taken place. Yellow: Material is making slight property changes. Green: The physical change has completed its cycle and its function is satisfied. Red: The material has passed its operating range and has degraded in some form. Rectangle Denotes a film or sheet. Oval Denotes adhesives, coatings. Dotted line Represents an ink or metal.

10 Split core copolymer card 120 F (49 C) No bonding, all layers are loose

11 Split core copolymer card 140 F (60 C) embossing smoothing out

12 Split core copolymer card 160 F (71 C) glossy, air lakes evident

13 Split core copolymer card 180 F (82 C) Lakes decreasing, no corestock bonding

14 Split core copolymer card 200 F (93 C) Lakes gone, overlay adhesion increasing

15 Split core copolymer card 220 F (104 C) planished, no core bond

16 Split core copolymer card 240 F (116 C) Slight core bond

17 Split core copolymer card 260 F (127 C) 83 vicat core has bonded

18 Split core copolymer card 280 F (138 C) s fused solid

19 Split core copolymer card 300 F (149 C) Some corestock edge distortion

20 Split core copolymer card 320 F (160 C) distortion and flow, UV inks color unchanged

21 pvc overlay coated adhesive UV ink pvc corestock Split core, copolymer, UV ink pvc corestock UV ink coated adhesive pvc overlay overlay adhesive ink core F C corestock distortion and ooze, UV ink color good some core edge distortion same as vicat core bonded still no core to core bond still no core to core bond lakes gone, ov adhesion increasing smaller air lakes overlay glossy, air lakes ov embossing smoothing no ov adh, slight blocking, ov embossed

22 pvc overlay coated adhesive metallic screen ink pvc corestock Copolymer with metallic inks pvc corestock metallic screen ink coated adhesive pvc overlay mag stripe overlay adhesive ink core F C core edge distortion 5/8 inch core edge distortion 1/2 inch core edge distortion 1/4 inch core edge distortion 1/8 inch slight core distortion, cores bonded slight edge distortion, cores 4N lakes gone, ov bonded, cores 2N glossy ov, no lakes, cores 2N ov glossy, lakes, cores loose ov embossing smoothing, ov 4N slight ov adh, ov embossed, cores loose

23 pvc overlay white sealable polyester Type II White composite card pvc corestock white sealable polyester pvc overlay overlay PET to core PVC core F C center pvc core distortion destruct bond all layers destruct bond all layers N all bonds overlay 6N bond, cores 3N bond overlay 5N bond, cores 2N bond overlay 4N bond, cores 1N bond lakes gone, 2N overlay bond overlay glossy, air lakes, slight bonding overlay embossing smoothing all layers loose

24 pvc overlay coated adhesive UV ink pvc corestock High vicat core and overlay pvc corestock UV ink coated adhesive pvc overlay mag stripe overlay adhesive ink core F C corestock distortion and ooze, UV ink color good some core edge distortion same as 260, no edge distortion vicat core bonded still no core to core bond still no core to core bond lakes gone, ov adhesion increasing smaller air lakes overlay glossy, air lakes, mag glossy ov embossing smoothing, magstripe bumpy no ov adh, layers loose, ov embossed

25 pvc overlay coated adhesive pvc homopolymer corestock Homopolymer corestock pvc homopolymer corestock coated adhesive pvc overlay hi co magstripe overlay adhesive cores F C corestock distortion and ooze 1/4 inch some core edge distortion 1/8 inch core to core bond destruct, no edge distortion core to core bond 12N core to core bond 6N slight core bond 4N lakes gone, ov adhesion increasing, cores 1N glossy, smaller air lakes overlay glossy, air lakes ov embossing smoothing no ov adh, ov embossed

26 pvc overlay coated adhesive metallized polyester laminating adhesive pvc corestock Metallized polyester card pvc corestock laminating adhesive clear polyester coated adhesive pvc overlay magstripe overlay adhesive cores foil F C aluminum cracking, core edge distort 1/4 inch core edge distort 1/8 inch, orange peel grainier core edge distort 1/8 inch, orange peel grainier cores sealed, orange peel grainier cores 4 N cores 2N same as 180, foil best orange peel look overlay glossy, back planished, foil front smooth overlay glossy, air lakes, core loose ov embossing smoothing no ov adh, slight blocking, ov embossed

27 pvc overlay toner ink Digital pvc corestock pvc corestock toner ink pvc overlay overlay inks cores F C distortion, inks crack distortion, inks crack distortion, inks crack cores sealed, edge distortion 3/4 inch cores 8 N, edge distortion 1/2 inch cores 2 N, edge distortion 1/4 inch ov glossy, cores 1 N, edge distortion 1/8 inch ov glossy, no lakes, cores loose, some distortion ov glossy, lakes, cores loose, core straight ov smoothing, cores loose, core straight ov embossed, cores loose, core straight

28 pvc overlay adhesive toner ink pvc corestock Digital with ctd overlay pvc corestock toner ink adhesive pvc overlay overlay adhesive inks cores F C edge distortion 1/2 inch edge distortion 1/4 inch cores sealed, edge distortion 1/4 inch cores sealed, edge distortion 1/8 inch cores 5 N, edge distortion 1/16 inch cores 1 N, edge distortion 1/16 inch cores 1 N, no core distortion ov bonded, no lakes, cores loose ov glossy, lakes, cores loose, core straight ov smoothing, cores loose, core straight ov embossed, cores loose, core straight

29 What changes take place? Thermoplastic changes: PVC embossing will gloss out s will activate s change s soften Foils flow Magstripes planish

30 activation Degree Peel N/cm Degrees F Avg 3 competitive adhesive formulas. Avg 3 UV ink colors.

31 activation Peel N/cm degrees F Three adhesive formulas. Average 2 UV ink colors.

32 Vicat ISO 306 ASTM D1525

33 Thermoplastics PVC APET & PETG coating Varnish Screen ink Magnetic stripe adhesive PLA (corn)

34 Thermosets OPET Holographic foil Magnetic stripe Wires, chips, antennae UV cured ink Toner based ink

35 Summary Each card construction type has a different melt profile Vicat can help determine core reaction s can provide solutions Holographic foils present challenges Magnetic stripes have thermal properties Wires, modules, OPET don t soften Toner based inks are not heat compatible

36 Lamination

37 Thank You! Thank you for your attention. Questions? Discussion. Need this presentation in PDF form? Bill at