Vacuum coating technologies for
superior transfer efficiency

Vacuum coating technology

One of the key advantages involved in vacuum application technology is the degree of transfer efficiency achieved - almost 100% - meaning close control over lacquer consumption and very little waste – all adding up to significant savings while achieving superb coating quality.

Until recently, this technology was used for edges, in terms of coating, sealing or even waterproofing. Today, we have developed vacuum application solutions for flat panels as well as edges, which can be of all shapes and sizes.

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Flat panels

Manufacturers of cabinet doors, panels and bathroom furniture will welcome the recently released vacuum application machine, Smartvacuum. Any wood or wood-based flat panel can be coated using this technology, especially those with rounded edges.

Vacuum application avoids contact between the application head and the substrate. This enables clean, efficient processing using 100% UV acrylic paint in a single pass. Up to 140 g/sqm are deposited homogeneously, thereby avoiding product build-up on any sections of the panel. The process is simple, clean, eco-friendly and cost-efficient. Flash-off is performed after basecoat application and prior to the panel completing its drying in a UV-R oven. Using a 100% solid UV product, this makes it a relatively sustainable process and the coating is more stable over time compared to polyurethane or polyester-based products.

Edges

Vacuum application machines for edges have been around for longer, some of which combine sanding operations as a complete solution. We provide 3 different systems according to specific needs.

The perfect match for Smartvacuum is Smartedge, a machine which handles straight and shaped panel edges. Featuring our patented Inert Coating technology for filling the edges of MDF or chipboard panels, it generates a smooth surface or recreates the grain effect. The vacuum system will coat any type of edge as the application head adapts to each shape. When fitted with Edge & Go, consisting of an application head with interchangeable straight or shaped slats, changing from one edge shape to the next is accomplished without turning off the vacuum tower. In terms of speed, switching from a straight edge with a 3 mm radius to a J-Pull handle edge, for example, takes less than 15 seconds.

Smartvacuum and Smartedge use the same technique and the same lacquer. That makes it simple to achieve the best junction seam between the flat surface and the edge of the panel.

Sealing solutions

Sealing operations are performed to protect the integrity of a product by ensuring the edges are not vulnerable to humidity for example, something which compromises the durability of a panel or other item.

Vacuum systems for the sealing of edges include another machine in our range: Talent is a patented solution for the sealing of the shaped edges of laminated panels, coated with quick-drying water-based products for application on various types of material. Used as a sealing technique for items found in several sectors, including panels, mouldings, fibreglass ceiling panels, polycarbonate sheets, fibre cement tiles and many other materials used in the construction industry, Talent works with water-based coatings, also suitable for UV curing, 100% UV acrylic paints, sealants (wax, paraffin, glue).

Edge impregnation

A solution dedicated to sealing the edges of panels is required when the risk of water penetrating the panel is an issue. In certain instances, cabinet doors, but more frequently panels for flooring applications will need to have their edges well sealed so as to avoid quality decreasing over time. Hybrid implements a patented*  technique to impregnate the panel edge with a special UV polyurethane glue to protect against humidity and other harmful elements.

Frequently Asked Questions

哪些基材适合真空涂装?

真空涂装适用于木材及其衍生物、金属、石膏板、复合材料和PVC型材。

这种技术非常适合于…?

当进行大批量型材涂装时,此技术是理想选择,可实现高水平的生产效率。

真空涂装的优点是什么?

这项技术有很多优势。 首先,传输效率达到惊人的99%。 真空涂装机体积小,因此占用的工厂空间很小。,使用真空涂装机,可一站完成360°砂光,型材涂装和漆膜固化,使生产效率得以优化。 没有空喷漆雾,不对环境造成任何污染。 漆膜厚度高,以玻璃棉面板为例,漆膜厚度可达700 µm。

如何评估漆膜质量?

对漆膜质量的评判带有很强的主观性。 但是,如果产品对漆膜硬度要求较高,那么该技术通过使用固体含量为80%的涂料,可以实现较高的漆膜厚度(例如,天花板可达到700 g / m2),并同时减少干燥段费用。即使是较复杂的型材,稳定的漆膜厚度也是真空涂装技术在质量方面的关键优势。。

在真空涂装过程中,我需要考虑哪些消耗因素?

这将取决于你是使用紫外线固化涂料还是水性涂料。使用UV涂料,真空涂装机每道油漆涂布量为25至75µm(1至3 mills),而使用水性涂料,真空涂装机每道油漆涂布量为25至150µm(1至6 mills)。您还需要考虑电能消耗和压缩空气消耗。

真空涂装可加工工件的尺寸范围是多少?

最小长度为915 mm(36“),最大宽度为305 mm(12”)。这个范围之内的任何尺寸都可以。

清洁真空涂装机需要多长时间?

清洗时间根据机器大小和所用油漆的类型而不同。水性涂料所需的时间比粘性紫外线涂料短。平均来说,更改配置文件时,需要10到15分钟。如果您还需要改变颜色,需要30分钟。

涂料消耗量是否可控?

可以。通过调整模板开合度、真空压力和涂布速度,可以控制涂层厚度和涂料消耗。在使用UV涂料时,涂料粘度可以通过温度进行控制,并进一步影响涂料消耗量。

除了真空涂装机,还需要哪些设备来完成整个流程?

为了使生产流程更流畅,可以配备进料和出料输送机。任何情况下,我们都可提供包括材料制备、涂装和干燥在内的全套解决方案。边部涂装机通常安装在现有的双端开榫机上,以实现更精确的工件导向,避免过度喷涂。

设备灵活度如何?

由于真空涂装适用于大批量相同或相似类型的型材,因此柔性不是该设备或工艺的关键特征。当切换型材类型时,用户只需变更模型或喷头。

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