FLEX BANNER SUBSTRATE USED IN DIGITAL PRINTING
[EIRI/EDPR/1010] J.C.: 9649
INTRODUCTION
Polyester/vinyl chloride polymer laminates used as Flex Banner
It has been found difficult to produce laminates of linear polyesters such as polyethylene terephthalate and vinyl chloride polymers since these two types of polymers do not usually adhere well to each other; indeed polyethylene terephthalate is often used as a release layer for sheets or films of vinyl chloride polymers.
This method provides a well adhered laminate of a synthetic linear polyester and a plasticised vinyl chloride polymer, the effective bonding between these two particular polymers being promoted by an intermediary primer coating comprising a certain polymeric composition.
According to the present method there is provided a laminate comprising a layer of a synthetic linear polyester, a plasticiser-free polymeric primer coating applied to at least one surface of the polyester layer and comprising a cross-linked composition comprising a polymer of at least one monomer selected from the esters of acrylic acid and methacrylic acid, and at least one layer made from a plasticised vinyl chloride polymer composition which is bonded to the linear polyester layer through the intermediary of the primer coating.
According to another apsect of the method there is provided a process for the production of a laminate which comprises applying an aqueous or organic dispersion of a polymeric primer composition to at least one surface of a layer of a synthetic linear polyester, said primer composition comprising a plasticiser-free cross-linkable composition comprising a polymer of at least one monomer selected from the esters of acrylic acid and methacrylic acid, removing the dispersing medium and cross-linking the primer composition, and bonding to one or both sides of the polyester layer, through the intermediary of the primer coating so formed, a layer made from a plasticised vinyl chloride polymer composition.
According to a further aspect of the method there is provided the use of a plasticiser-free cross-linkable composition, comprising a polymer of at least one monomer selected from the esters of acrylic acid and methacrylic acid, for the production of a primer coating for a layer of a synthetic linear polyester which coating acts, when cross-linked, as an adhesion-promoting agent between the layer of polyester and a layer made of a plasticised vinyl chloride polymer which is bonded thereto.
The above defined primer coating promotes excellent adhesion between the linear polyester layer and the plasticised vinyl chloride polymer layer. An example of a composition used for the primer coating comprises a copolymer of ethyl acrylate, methyl methylacrylate and methacrylamide, which has been cross-linked with an ethylated melamine/formaldehyde condensation product. The primer composition is preferably cross-linked with the aid of a suitable added cross-linking catalyst, e.g. ammonium chloride, ammonium nitrate, ammonium thiocyanate, ammonium dihydrogen phosphate, ammonium sulphate, diammonium hydrogen phosphate, para toluene sulphonic acid, maleic acid stabilised by reaction with a base, or morpholinium para toluene sulphonate. The cross-linking is preferably effected before the laminating operation begins.
COST ESTIMATION
Plant Capacity 2400 sq.ft./Day
Land & Building (1000 sq.mt.) Rs. 65.00 Lac
Plant & Machinery Rs. 17.00 Lac
Working Capital for 3 Months Rs. 48.77 Lac
Total Capital Investment Rs. 1.33 Cr
Rate of Return 83%
Break Even Point 31%
CONTENTS
INTRODUCTION
POLYESTER/VINYL CHLORIDE POLYMER LAMINATES USED AS FLEX BANNER
METHOD 1
METHOD 2
INTRINSIC VISCOSITY
STIFFNESS
WEAR LOSS
DENSITY OF EACH OF THE FILMS CONSTITUTING THE LAMINATE FILM
METHOD 1
METHOD 2
METHOD 3
METHOD 4
METHOD 5
METHOD 6
METHOD 7
DROP-OUT
STIFFNESS
WEAR LOSS
METHOD 9
METHOD 10
METHOD 11
METHOD 12
METHOD 13
METHOD 14
LAMINATED POLYESTER FILM AS FLEX BANNER
(GRAFTED MOIETY OF POLYESTER GRAFT COPOLYMER)
(POLYMERIZATION INITIATOR AND OTHER ADDITIVES)
(POLYESTER BASE FILM)
1) ADHESIVE PROPERTY I
2) ADHESIVE PROPERTY II
3) HYDROGEN BONDING COMPONENT OF THE SURFACE ENERGY (ΓS H)
4) BLOCKING PROPERTY
5) GLASS TRANSITION TEMPERATURE (TG)
6) APPARENT SPECIFIC GRAVITY
7) PERCENT LIGHT TRANSMISSION
METHOD 1
METHOD 2
METHOD 3
POLYESTER LAMINATES USED AS FLEX BANNER
(I) EVALUATION OF POLYESTER RESINS
(IA) CONTENT OF CYCLIC ACETAL DIOL UNITS
(IB) GLASS TRANSITION TEMPERATURE
(IC) INTRINSIC VISCOSITY
(ID) MELT VISCOSITY
(IE) MELT STRENGTH
(II) EVALUATION OF LAMINATE WITH BACKING PAPER
(IIA) MOLDABILITY
(IIB) HEAT SEAL STRENGTH
(IIC) FRAGRANCE PRESERVATION
(IID) ADSORPTIVITY
(III) EVALUATION OF LAMINATE WITH BACKING RESIN FILM
(IIIA) HEAT SEAL STRENGTH
PRODUCTION METHODS 1-2
METHOD 1
METHOD 2
METHOD 3
METHOD 4
LAMINATED POLYESTER FILM AND LAMINATED FILM AS FLEX BANNER
METHOD 1
METHOD 2
HIGHLY PLASTICIZED LAMINATED VINYL FABRIC
IT IS THEREFORE AMONG THE OBJECTS OF THE PRESENT METHOD TO PROVIDE:
EXTRUSION
TOP COATING - LUSTER CONTROL
TOP-COATING APPARATUS
LAMINATION
FABRIC CONSTRUCTION - FIGS. 2 AND 3
VINYL CHLORIDE POLYMER LAMINATE
METHOD 1
MANUFACTURING PROCESS OF LAMINATED POLYESTER FILM
[POLYESTER FILM]
[COATING LAYER]
[POLYMER BINDER]
POLYESTER 1:
POLYESTER 2:
ACRYLIC 1:
ACRYLIC 2:
URETHANE:
FINE PARTICLES 1:
FINE PARTICLES 2:
INDUSTRIAL FEASIBILITY
METHODS OF MANUFACTURE
MANUFACTURER/EXPORTER
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)