EDGEBAND PROGRAM MAtERiAl AND PROCESSiNG tiPS Construction www.rehau.com

EDGEBAND PROGRAM MAtERiAl AND PROCESSiNG tiPS Construction www.rehau.com
EDGEBAND PROGRAM
Material and PROCESsING Tips
www.rehau.com
Construction
Automotive
Industry
REHAU EDGEBAND materials
overview
PVC Edgeband
PVC – no other polymer is as versatile. For
decades it has been indispensable for its price to
performance ratio. REHAU PVC edgeband continues to be a popular edging solution. The material
can be recycled, is self-extinguishing and has a UV
light fastness ISO 4892-2 rating of 7. Semi-rigid
PVC is capable of making tight radii on contour
processing machinery.
ABS Edgeband
ABS is another thermoplastic material. This impact
resistant, tough material has many economic
and processing advantages. It can be recycled or
incinerated. REHAU ABS edgeband is highly heat resistant, has a UV light fastness ISO 4892-9 rating of
6 and can be processed on standard edgebanders.
PP Edgeband
Polypropylene edgeband has become very popular
in the furniture industry in recent years. This material, with its soft cross-linked surface is environmentally sound. It requires very little energy to
manufacture and can be recycled or incinerated.
During incineration, it produces only carbon dioxide
and water (as does natural gas). REHAU PP edgeband is suitable for use on standard edgebanders
or on contour processing machinery. Our universal
primer system guarantees optimum bonding of
the edging with hotmelt adhesive made of EVA/
PA or PUR. The edgeband has a UV light fastness
ISO 4892-9 rating of 7. It is extremely resistant to
heat and solvents, and has low shrinkage. PP is
capable of making tight radii on contour processing
machinery.
PMMA
Acrylic (PMMA) is a high, quality, proven thermoplastic material. PMMA has excellent light transmission and outstanding resistance to weathering and
aging. In addition, PMMA has a high surface hardness and scratch resistance, and does not contain
cadmium or lead and fulfils PAH Category 2.
2
Range
PVC
ABS
PP
Solid
˜
˜
˜
Printed
˜
˜
˜
NaturEdge®
˜
˜
˜
SoftEdge™
˜
PET
˜
Magic™ Translucent Metallic
˜
Magic™ Metallic
˜
Magic™ 3D/ Visions™
Properties
PMMA
˜
PET
PVC
ABS
PP
Light fastness to ISO 4892-2
7 to 8
>6
7 bis 8
Shrinkage at 194°F (90°C)*
< 0.3%
< 0.3 %
< 0.1 %
Shrinkage at 230°F (110°C)*
< 1.7%
< 1.7 %
< 0.2 %
≤ 1.0%
162°F (72°C)
185°F (85 °C)
212°F (100 °C)
> 80°C
79 ± 4
70 ± 4
73 ± 3
80 ± 3
Ball test hardness to DIN 53456
95
103
98
Recycling
˜
˜
˜
˜
˜
˜
˜
PVC
ABS
PP
PET
PMMA
Primer system
˜
˜
˜
˜
˜
Hot melt adhesive EVA/PA/PUR
˜
˜
˜
˜
˜
Processing
PVC
ABS
PP
PET
PMMA
End milling
˜
˜
˜**
˜*
˜*
Vicat
Shore hardness
Incineration
Gluing
PMMA
>6
Flush milling
˜
˜
˜**
˜*
˜*
Radius milling
˜
˜
˜**
˜*
˜*
Contour milling
˜
˜
˜**
˜*
˜*
Scraper
˜
˜
˜**
˜*
˜*
Polishing
˜
˜
˜**
˜*
˜*
* Test carried out in loose storage for one hour (bonding reduces shrinkage)
** Optimum tool configuration required.
3
edgeband processing
Tips and hints
We provide these tips to ensure your success in
processing thermoplastic edgeband. The REHAU
edgeband range is manufactured to the latest state
of technical knowledge and can be processed on
all conventional hotmelt adhesive edgebanders and
CNC machinery.
Surface Properties
REHAU printed edgeband is manufactured with
sophisticated, reproducible processes. Printing and
lacquering are carefully tuned manufacturing steps.
The acrylic lacquer UV coating ensures resistance
to scratches and mechanical abrasion.
Material Properties
REHAU edgeband is extruded from PVC, ABS, PET,
PP or PMMA. It is formulated to ensure even coloring of the material and clean, trouble-free edge
finishing. Optimal material formulations guarantee
long life of the milling and cutting tools.
They resist a 24-hour test with domestic cleaning
agents and are impervious to stains. The surfaces
can be washed, are hygienically clean and resistant
to moisture.
REHAU edgeband is light fast. During testing to EN
ISO 4892-2, the sample is subjected to UV lighting behind window glass under defined physical
parameters. Simultaneously, a light sensitive scale
is equally exposed. As soon as level 6 on the scale
has been reached, the sample is compared to an
unexposed sample (based on ISO 105-A02/A03).
REHAU edgeband also resists saliva and sweat according to DIN 53160, parts 1 and 2.
Tolerances
Adhesion Properties
REHAU edgeband is produced with a universal
primer suitable for bonding with EVA, PA , PUR and
APAO hot melt adhesives.
The new high temperature resistant EVA hot melt
adhesive provides, particularly when used with our
low shrinkage REHAU edgeband, secure adhesion
even with edging of more than 3 mm thickness. We
recommend APAO adhesive for high ambient conditions, for example in kitchens or when furniture is
exported in containers.
Wall Thickness
Allowed Deviation* in mm
0.4 – 0.8 mm
± 0.05
0.9 – 1.0 mm
± 0.10
1.1 – 1.6 mm
± 0.15
1.7 – 3.0 mm
± 0.25
3.1 – 5.0 mm
± 0.30
Width in inches
Allowed Deviation* in
Width in mm
Allowed Deviation** in mm
7/16" – 11/16"
± 0.008"
11 – 17
± 0.2
11/16" – 1 5/16"
± 0.012"
18 – 33
± 0.3
1 5/16" – 1 9/16"
± 0.016"
34 – 40
± 0.4
over 1 9/16"
± 0.020"
over 40
± 0.5
*Special tolerances available upon request
4
Tolerances
During quality control, REHAU edgeband is checked
for compliance with surface quality standards and
dimensional tolerances.
**For edgebands with thickness > 1 mm
For applications with high moisture conditions, we
recommend a PUR hot melt adhesive.
REHAU edgeband is not suitable for a cold gluing
process. For processing on special edgebanders
with hot-air guns, certain REHAU edgeband ranges
can be supplied with pre-coated hot melt adhesive.
Note: We recommend processing trials for edgeband that is pre-coated with hot melt adhesive.
Edgeband of less than 1.5 mm thickness can be
distorted by the re-activating heat application.
Storage
REHAU edgeband can be stored almost indefinitely
at room temperature (68-77°F [20-25°C]).
Exceptions: REHAU PVC/PP SoftEdge™ sealing
edgeband and edgeband with pre-coated adhesives
may not be stored longer than 6 months. After this
period, the reactivation of the adhesive may be
affected.
To prevent spontaneous adhesion between layers,
the storage temperature of edgeband should not
exceed 77°F (25°C).
Processing Parameters
For clean and permanent covering of edges with
edgeband, it is necessary to observe a variety of
processing parameters depending on the materials
(i.e. edge, adhesive), the edgebanding machinery
and the ambient temperatures. In each case, it is
advisable to conduct trials to determine the optimal
operations and settings. The standard values
specified by the manufacturers for the respective
applications should be observed.
Processing Temperature of Adhesive
The specifications in the adhesive suppliers’ data
sheet should be observed. The specified temperature range depends on the ambient conditions and
the processing speed.
Note: Thermostats in the glue containers are often
inaccurate and can deviate by several degrees from
the actual temperature on the spreader roll.
Processing Temperature of Board and Edging
When applying edgeband, room temperature should
be at least 64°F (18°C). Avoid drafts.
Note: If board and edging are too cold (i.e. stored
in unheated rooms), the hot melt adhesive applied
to the board will set before the edgeband has been
applied.
– Storage of hot melt adhesive: cool and dry
– Wood moisture content of board material: 7-10%
5
Edgeband processing
Tips And HinTs
Fixing Quality
Fixing quality depends on:
– Base material
– Milling quality
– Choice of adhesive
– Glue temperature and amount
– Temperature of boards and edgeband
REHAU edgeband tolerances ensure optimum pressure in the fixing area.
Milling
Milling is to be done in counter-rotation (power cut).
PMMA and PP edgebands and critical colors require
careful observation.
End Milling
REHAU edgeband of up to 3.5 mm thickness can be
processed from the roll and cut. Thicker dimensions
are generally processed in fixed lengths from a feed
dispenser.
Rate of Feed
The following settings are recommended:
– Nozzle spreader at 39-82 ft (12-25 m) per
minute
– Spreader roll at 59-197 ft (18-60 m) per minute
Removal by Suction
More powerful removal of milling chips is necessary
for thermoplastic edging than for thermo-set edging, because the thermoplastic chips can become
statically charged and “stick" to the material. It can
be removed by suction at approximately 88 ft3/s
(2.5 m3/s).
6
Machine rotation speed rev/min x 100
Amount of Adhesive to be Applied
Hot melt adhesives should be applied at a volume
of 0.03-0.04 lbs/ft2 (160-220 g/m2). Adhesive
application should be even, and the volume should
fill the hollow areas between the wood chips and
should cause small pearls to be pressed out from
under the edging. The amount of adhesive required
depends on the thickness of the board, the thickness of the edging material (more adhesive is
used for thick edgeband) and the rate of feed (the
slower the rate, the larger the amount of adhesive
required).
Diameter in mm
Speed m/sec
Wheel material sisal-muslin felt (hardness 0.56 g/cm)
Buffing
For all PP edgeband and darker colors in other
materials, the following buffing procedures must be
observed.
Recommended cutting speed for thermoplastic
materials:
– Grinding at 26-49 ft/s (8-15 m/s)
– Polishing at 16-49 ft/s (5-15 m/s)
Depending on the diameter of the buffing wheel
from 1,000-2,000 rev/min.
Intermediate Storage
After applying the edgeband, the furniture components should be stored for 24 hours to ensure the
crystallization of the adhesive.
Painting of Edgebands
REHAU ABS, PVC or PP edgeband may be painted.
Special PUR-based paints such as DD paint should
be used. The choice of paint systems should always
be agreed with the manufacturers. Suitability should
also be tested prior to mass production.
The following steps may be observed:
– Pre-treatment with a DD thinner
– Pre-priming of PP edgeband
– Single- or double-spray painting in the required color
– Intermediate drying for 45 minutes at 68°F
(20°C)
– Final drying overnight at 68°F (20°C)
7
Edgeband Processing
Tips and hints
Work Cycle in Edgebanding Machine
1 Gluing
2 Cutting
3 Pre-milling with power cut
4 Chamfering with power cut
5 Cleaning
6 Buffing
Machine Set-up in Relation to Material Properties
– Thermoplastic material should be processed
counter to board travel. Processing in the same
direction can lead to deterioration in quality.
– The scraper must be at a 90° angle to the
material. The scraper should remove
0.004"-0.006" (0.10-1.15 mm).
– The position of the buffing station, the cutting
speed (m/sec) and the quality of the buffing
wheel must be adjusted to suit the specific
edgeband material.
– As the decorative design is applied to the reverse
side of PMMA edgeband, ensure that normal
processing does not cause damage, particularly
during edgeband feeding. Rubber rollers should
be used instead of steel rollers at the feed stage.
– It is recommended to use blunt tip scrappers for
PMMA.
8
– Check carefully that release and cleaning agents
do not contain alcohols and solvents and do not
come in contact with PMMA. Static inhibitors
and/or cooling agents create tension in the
edgeband due to the cooling of the adhesive joint
which results in cracking.
– When applying PMMA edgeband around tight
radii ensure that the material is sufficiently
heated. Due to the brittle nature of PMMA, the
application of heat using an external source
(IR radiators or hot-hair blowers) can reduce the
size of radius that can be achieved.
– The outer radius should be cleaned on a sample
board with a plastic cleaner in order to check
whether the selected processing parameters are
sufficient during radius processing.
Processing Tips for Polypropylene (PP) Edgeband
Target for quality that does not need re-working: sz = 0.20 to 0.25
sz =
Processing Speed v (m/min) x 1,000
Routing Speed n (r/min) x Number of Blades z
Number of Blades z
Routing Speed (r/min)
Routing Speed (r/min)
12,000
18,000
3
(0.55)
(0.37)
4
(0.41)
0.27
5
(0.33)
0.22
6
0.27
0.18
No. of blades
cutting length per tooth sz :
S
S
sz for varying speeds/ numbers of blades
at 20 m/min processing speed
Miller fitted with carbide tipped blades
Blades are well adjusted
Miller fitted with diamond tipped blades
Blades are well adjusted
Cutting speed of miller
Approx. 70 m/sec
Processing speed (m/sec)
Approx. 25 m/min (does not depend on material)
Copy milling (m/min)
Max 22 m/min
Volume to be machined
1 to 2 mm projection from the board
Choice of Miller
mo
tor
axis
30
Installation is critical
15
Miller with adjustable blades
15
9
Edgeband Processing
trouble shooting
Hints and Tips for Processing Faults
Description of Problem
10
Possible Causes
1.
The edging can easily be pulled off by hand. Adhesive
remains on the chipboard (throughfeed technique) or on
the edgeband (stationary technique). The grid pattern of
the adhesive application roller is visible.
-- Room temperature is too low or there is a draft in the
interval between application of adhesive and contact with
the pressure roller
-- Edging material (throughfeed technique) or chipboard
(stationary technique) is too cold
-- Adhesive temperature is too low
-- Rate of feed is too slow
-- Not enough pressure from application roller
2.
Edging can easily be pulled off by hand. Adhesive
remains on the board. Surface of the adhesive is
completely smooth (edging slides off).
-- Board and/or edging are too cold
-- Primer is faulty or an incorrect type for the application
3.
Edging can be pulled off by hand. Adhesive remains on
the edging.
-- Board material retains too much residual heat (i.e. after
the preceding veneering/laminating of the board surfaces).
4.
Poor adhesion of the edging on the front end of the
board. The edging has splintered at the front end.
-- Adhesive application roller protruding too far into the path
of the board. No adhesive applied to the front of the board
due to strong pressure setting of the roller, causing it to
bounce back.
5.
Milling cut visible.
-- Feed rate too fast
-- Cutting speed too slow
-- Rework with scrapers and/or buffers
6.
The color tone in the milled area is slightly lighter on the
thick edgebands.
-- Cutting speed too slow
-- Hot air stations should be used
-- Buffing
7.
Glue joint is not sealed (processing center).
-- Contact pressure too low
-- Curvature of edgeband too high
-- Check hot melt adhesive type (insufficient heat adhesion)
-- Edgeband pre-tensioning is incorrect
-- Adhesive does not set in adequate time
8.
Glue joint is not sealed (straight line).
-- Adhesive too cold
-- Adhesive application too low
-- Contact pressure too low
-- Edgebands pre-tensioning incorrect
-- Scoring saw alignment incorrect
-- Contact between the adhesive application roller and board
-- Debris not removed from board cross-section
9.
Edgeband splits during the milling process.
-- Edgeband vibrates during the milling process
-- Insufficient adhesion
-- Edgeband projection too large
10. Stress whitening occurs in milled area, especially after
scraping.
-- Chip of the scraper too thick
-- Scraper set up incorrectly
11. Stress whitening occurs during processing center.
-- Processing temperature is too cold
-- Radius too small
REHAU TOOLS
INNOVATIVE TOOLS FOR EDGEBAND PROCESSING
Optimal, Manual Edge Processing Using REHAU
Tools
REHAU provides innovative tools for the complete
edgebanding process – from gluing through finishing. The tools are adjusted to the special require-
1 Guillotine End Trimmer
Trims the edgeband ends with precision
4 Edge Cutter*
ments of processing thermoplastic edges (ABS,
PET, PMMA, PP, PVC). They are ideal for individual
and small series production, for processing of
special panel shapes and for low-noise, high-quality
finishing on site.
2 Guillotine End Cutter*
Creates nearly invisible butt joints on both
straight and radiused sections
5 Plane Cutter*
3 Polishing Felt and Heat Gun
Finishes the joint adhesion
6 Finisher
Flush trims band ends with precision
Creates internal and external radiused
edges
Sands edges to eliminate processing
traces
7 Polisher with Flap Wheel
Smoothes and rounds edges after trimming
8 Sponge Sanding Block
Deflashes edges that cannot be radiused
* Available from the Express Collection
stock program
11
REHAU edgeband
any questions?
REHAU
East Coast / Central U.S. (888) 734-2810 West Coast U.S. (800) 944-1011
Eastern Canada (800) 361-0830 Ontario, Canada (800) 561-9609 Western Canada (800) 668-1173
Celaya, Mexico (800) 917-3428 Monterrey, Mexico (81) 8121-0130 Panama City, Panama (507) 83 05 257
For updates to this publication, visit na.rehau.com/resourcecenter
The information contained herein is believed to be reliable, but no representations, guarantees or warranties of any kind are made as to its accuracy, suitability for particular applications or the results to be obtained therefrom. Before using, the
user will determine suitability of the information for user’s intended use and shall assume all risk and liability in connection therewith. To the extent permitted by law, REHAU EXPRESSLY DISCLAIMS ALL IMPLIED WARRANTIES, INCLUDING BUT
NOT LIMITED TO, ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE.
© REHAU Incorporated 2010 Printed in USA
www.rehau.com
[email protected]
100.711 en 09.2010
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