The Metallizing Process The substrate (plastic film or paper) is loaded into the chamber via automatic loading systems or by crane/hoist.
The substrate is threaded through the winding system.
The chamber is sealed and evacuated to a high vacuum environment (<4 x 10-4 mbar).
The evaporation process deposits a uniform aluminum coating on the substrate surface which is measured and monitored across the web and from start to end with on-line optical monitors.
High purity aluminum wire is fed onto ceramic boats situated across the width of the web. The aluminum vaporizes from the surface of the boats. The boat's temperature is approximately 1,500°C.
As the metal vaporizes, coils of aluminum wire continually feed onto the surface of the multiple ceramic boats. Evaporation takes place at a rate of approximately 7 to 10 grams of aluminum per minute.
A cooling drum is positioned directly above the evaporation area. As vacuum metallization begins, the roll of material is fed through the evaporation area, where it travels around the process cooling drum. The aluminum vapor rises straight up the drum, where it condenses on the substrate's surface.
The new Galileo equipment also includes an air cooling element which provides a thin layer of air between the substrate and the process drum for additional cooling.
The amount of metal deposited on the substrate depends on several variables:
the ceramic boat's temperature, the speed of the substrate as it travels through the evaporation area, the speed of the aluminum wire feed onto the boat's surface and the atmospheric pressure within the chamber.
Plasma treatment is available for film in 3 of Vacumet's new Galileo metallizers.
Plasma treatment is a process that cleans and chemically functionalizes the polymer surface resulting in improved metal adhesion. Plasma treatment is applied inside the vacuum chamber just prior to metallization, maximizing the effectiveness of the treatment. Plasma treatment has been proven to improve metal adhesion and barrier properties.
*Vacumet encourages recycling. VACU-BRITEŽ and HoloPRISMŽ papers are recyclable.
Please check recyclability of post processing (inks, adhesives, boards).
