How To Produce Good Surface PVC Wall Panels?

1. What are PVC wall panels?

The raw material for PVC wall panels is PVC and a surface film. It’s used to make wall decorations. Wall panels made of PVC are slowly replacing traditional wall building materials. There are lots of ways to shape wall panels. 3D printing and film are the most common methods.

PVC wall panels with smooth surface are great. The smoothness of PVC wall panels can be affected by several factors. Raw material formula, die head, conical twin screw barrel structure, and water recycling are some of these.

Here, HUACHEN Screw would introduce PVC wall panel processing in two ways: What factors influence PVC wall panel smoothness, and how to improve it?

2. What factors influence PVC wall panel smoothness?

2.1 PVC wall panels formula

The formula is the key to making quality PVC wall panels. The decomposition temperature of PVC is lower than its processing temperature. As well as considering its stability, we should also consider its processing properties.

Lubricants play a big role in this formulation system. By adjusting the lubricant content, you can control the plasticizing level of PVC panels. It is also possible to adjust the internal and external lubricants in order to control the release performance of PVC wall panels.

2.2 Die head, or mould

Die head runner structure and processing accuracy will directly affect the smoothness of finished PVC wall panels, especially co-extruded runner structures for compound profiles. Die runners also affect how much heat the material gets. Because a longer die runner means a longer heating time and more plasticization.

Then the extruded high temperature material passes through the die head under vacuum pressure. Smooth out the PVC wall panels by providing friction. That means more vacuum pressure during moulding, a tighter fit inside the runner, and a better PVC wall panel.

2.3 Screw barrel structure

The plasticising level affects PVC wall panels’ surface, which is affected by extrusion. If the processing temperature is low, PVC does not fully plasticize and melts. The panel’s surface will look rough and dark. When it’s hot, over-plasticization or decomposition can happen. It is yellow without any natural brightness. Conical twin screw extruders are commonly used to make PVC wall panels. Conical twin screw extruder barrels affect PVC plasticizing capacity and wear conditions too.

PVC wall panels should have specialized conical twin screw structures and barrel structures. Some conical screw is designed for PVC with a high filler CaCo3, while others are designed for PVC with a low filler CaCo₃. When placing an order, you should confirm the screw barrel structure with the screw barrel manufacturer.

A new conical twin screw barrel should consider the PVC filler level in some situations. PVC wall panels work best with screws and barrels explicitly made for them. However, after a long time, the gap between the screw and barrel will get wider. There’d be a PVC melting backflow problem in production. The wall panel appeared as a yellow product.

2.4 Circulating water

The smoothness of PVC panels can also be affected by the way circulating water cleans up. If the water has a lot of impurities, especially sediment, it will scratch and pit the product. To make the product look better, clean the sediment between the tank and the product.

3. How to improve PVC panel surface smoothness?

3.1 Formula design

A suitable PVC wall panel formula will ensure not only ideal plasticization of the product but also good die release qualities. The product should be coated with an oil film layer and have a smooth, bright surface after it’s extruded. If there’s no lubricant in the sharpening process, the oil film layer won’t be there. Lubricant consumption should be well controlled so products have a stable and smooth surface. Furthermore, lubricant consumption should be considered during the middle and late stages. Several lubricants, including stearic acid, oxidized PE wax, and calcium static, are combined to provide a smooth surface while simultaneously plasticizing.

3.2 Die head or mould

It should have a suitable co-extrude runner length and high inner processing accuracy. By adjusting the heating board, you get the perfect plasticizing temperature. Co-extrusion runners should be made longer in the die head design.

For example, 1500mm should be fine. When it lasts too long, it might cause black lines or crow’s feet. If it’s less than 1000mm, it’s useless. Additionally, there can’t be dead corners in the runner’s internal structure or the material won’t hold up. Then it burns the material and damages the machine.

PVC wall panels’ surface is also affected by the smoothness of a die head. The inner surface of the die head needs to be cleaned and polished very carefully. Use abrasion paste instead of sandpaper.

3.3 A better way to make PVC wall panels

1) PVC wall panels should have a smooth surface, and the processing temperature should be carefully controlled to ensure a good plasticizing result.

2) Make sure the co-extrusion temperature is controlled to ensure good plasticizing performance.

3) Make sure the vacuum pressure in the shaping mould is just right since heated materials should be tightly wrapped around the inside. Place a wax-absorbing plate in front of the first shaper entrance.

4) Make sure the shaping mould is empty while the machine is running. When fully filled with waste, it will give you instant feedback on the surface performance of the product. Furthermore, the vacuum pressure in the first shaping mould should be over 0.05MPa to make sure the product is wrapped close to the inner wall.

5) In some new types of dies and moulds, the pressure valve is mounted on top of the mould so you can control it easier. If you want good surface performance, turn it down or remove it. Because it affects the shape of the mould. The die processing temperature should be over 200°C so the material has high elasticity before going into the shaping mould.

Summary

Good surface PVC wall panels are primarily influenced by formula, conical twin screw barrel design, die or mould, and processing methods.

PVC wall panel formulas should consider the type of lubricant used. Conical twin screw barrels need a suitable structure according to the PVC wall panel formula. Die and mould lengths and structures need to be right. Plasticizing performance should be perfect regardless of the processing method. To shape moulds, you need sufficient vacuum pressure to wrap the material close to the inside.

There are three main ways to adjust. However, circulating water quality, water temperature, and screw speed can also affect the final product quality.

About the twin screw barrel Factory: HUACHEN

HUACHEN Screw has been a leading conical twin screw barrel manufacturer in Zhoushan Jintang since 1993. As one of the leading companies in designing and processing parallel and conical twin screw extrusion screw barrel, HUACHEN Screw can provide its customers with a wide range of services, including drawing rebuilding, design, modification, and customized screw barrels. Our company has also successfully exported and supplied screw barrels to customers worldwide.

>>Learn more about our company

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