Technical Manual

Technical Manual

Transparent PETG sheets

Griphen™ Frost

All information herein described is valid for both Griphen™ and

Griphen™ UV, unless stated otherwise.

CONTENTS OF THIS MANUAL

CHEMICAL RESISTANCE

FABRICATING

FORMING

BONDING & FASTENING

FINISHING

CLEANING

MAIN PROPERTIES

USEFULL ADRESSES

page 3

page 5

page 9

page 14

page 19

page 21

page 22

page 23

page 2

This information is given in good faith and to the best of our knowledge, but without warranty. Each user of our materials should determine himself the suitability for a specific application, and he is also liable for observing any proprietary or third party rights. It is always advisable to do preliminary testing.

Technical data concerning our products are typical values. Griphen™ is a trademark of ARLA PLAST AB.

Chemical Resistance

Griphen™ Frost shows a good resistance to a number of chemicals. The overall chemical resistance is however dependent upon the following parameters:

· temperature (resistance decreases with higher temperatures)

· stress level (best resistance is with flat sheet, clamped in a frame)

· chemical concentration (mostly in water, from some ppm to pure)

· exposure time (from fumes over drips to continuous contact)

Following information is meant as a guideline. As to the above influences, it is recommended to perform own testing according to the final application.

Do not hesitate to contact us in case of questions regarding the chemical compatibility of Griphen™ Frost.

In case you want Arla Plast to perform compatibility testing, the product and its MSDS, together with indications on above parameters are required.

In general, Griphen™ Frost shows a good chemical resistance for various chemicals such as dilute solution of acids, salts and aliphatic hydrocarbons, but it is significantly affected by aromatic hydrocarbons and ketones. All tests are performed on flat sheet, immersed in the reagent at room temperature

Reagent

Acetic Acid

Acetic Acid

Acetic Acid

Aceton

Aceton

Ammonium Hydroxide

Ammonium Hydroxide

Antifreeze, Automotive

Ethylen Glycol Type

Benzene

Brake Fluid, DOT3

Brake Fluid, off

Carbon Tetrachloride

Chromic Acid

Citric Acid

Cottonseed Oil

Deionized Water

Detergent, Alconox (0,25%)

Di(2-Ethylhexyl) Phthalate

Dibutyl Sebacate

Diesel Fuel

Dimethyl Formamide

Ethanol

Ethanol

Ethanol

Ethyl Acetate

Ethylene Dichloride

Gasohol, 10% Ethanol

Gasohol, 10% Methanol

5%

10% conc.

conc.

10%

40%

10%

50%

50%

100%

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1 a a b a ab a a a a a a a a a ab a a a ab a a

-

-

+

+

0

0

0

-

+

0

+

+

+

+

-

+

+

+

-

+

0

-

-

-

-

+

-

0 b a ab a b a a

1

1

2

1

1

1

1



page 3

Gasoline, Base for Gasohol

Gasoline, Premium Unleaded

Gasoline, Regular

Gasoline, Regular Unleaded

Gasoline, Regular Unleaded

Grease, Automotive

Hexane

Heptane

Hydrochloric Acid

Hydrochloric Acid

Hydrogen Peroxide

Hydrogen Peroxide

Isooctane

Kerosene

Lacquer Thinner

Methyl Alcohol

Mineral Oil

Motor Oil

Nitric Acid

Nitric Acid

Nitric Acid

Oleic Acid

Olive Oil

Phenol

Silicone Spray Lubricant

Soap Solution

Sodium Carbonate

Sodium Carbonate

Sodium Chloride

Sodium Hydroxide

Sodium Hydroxide

Sodium Hydroxide

Sodium Hypochlorite

Sulphuric Acid

Sulphuric Acid

Sulphuric Acid

Tapping Oil

Toluene

Toluene

Transformer Oil

Transmission Fluid

Turpentine

Water

Legend:

+ Resistant

0 Limited Resistance

- Not Resistant

Test condition:

(1) Stress free, immersion, 23°C, 1 year

(2) Stress free, immersion, 23°C, 30 days

Source:

(a) Eastman

(b) SK chemicals

5%

10% conc.

10%

3%

28% conc.

10%

40%

83%

5%

1%

2%

20%

10%

1%

10%

10%

3,5% conc.

3%

30%

-

-

-

-

-

-

-

0

0

+

0

+

+

0

+

+

+

+

-

+

-

+

+

-

+

0

+

+

+

+

+

+

-

0

+

0

+

-

+

+

+

+

+ a a a a b a a b a b a a a a a a a b a a a a a ab a a a a ab ab a a a a ab ab a b a a a a b

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

2

2



page 4

Fabricating

1 General

2 Sawing

3 Routing

4 Shearing, blanking, punching & die cutting

5 Drilling

6 Tapping

7 Milling

8 Laser cutting

1 GENERAL

General Guidelines

Griphen™ Frost sheet can be worked with most tools used for machining wood or metal. Tool speeds should be such that the sheet does not melt from frictional heat. In general, the highest speed at which overheating of the tool or plastic does not occur will give the best results.

It is important to keep cutting tools sharp at all times. Hard, wear-resistant tools with greater cutting clearances than those used for cutting metal are suggested. High-speed or carbon-tipped tools are efficient for long runs and provide accuracy and uniformity of finish.

Since plastics are poor heat conductors, the heat generated by machining operations must be absorbed by the tool or carried away by coolant. A jet of air directed on the cutting edge aids in cooling the tool and in removing chips.

Plain water or soapy water is sometimes used for cooling unless the trim scrap is to be reused.

Griphen™ Frost surface might whiten locally when stressed in cold state, like cold bending, die cutting, etc.

Also surface friction might cause similar discolouration. This effect can be reduced by local heating (hot air or flame), but will be very difficult to delete fully.

2 SAWING

Circular saw

The table saw type is the most frequently used for sawing flat sheet. When sawing thin gauge sheet, decrease saw speed, feed rate and pitch. Keep the gap between blade and table as small as possible.

Ensure that the table is free of particles that may damage the masking and scratch the Griphen™ Frost sheet.



page 5

Band saw

Band saws are used to cut out formed parts, or irregular shapes. For a series of the same shape, a supporting calliper can be useful in preventing chipping. Thicker gauges are best sawn with a bigger tooth size.

To achieve a smooth edge, circular saws and routers are preferable to a band saw.

Clearance angle

Rake angle

Tooth angle

Cutting speed (m/min.)

Tooth distance (mm) t

(larger for thicker sheet)

Trouble shooting

Band saw

20 - 40°

0 - 5°

-

600 - 1.700

1,5 - 3,5

Circular saw

10 - 30°

5 - 15°

15°

1.000 - 4.000

2 - 10

Chipping :Increase blade tooth size and saw speed, decrease feed rate.

Gumming: decrease blade tooth size and saw speed, increase feed rate.

Cracks or notches: as for chipping, check clamping.

In all cases, inspect blade sharpness, check blade fence alignment and if needed use air to cool blade. Change of sound or vibration during sawing, is an indication that sharpness and alignment might have changed.

3 ROUTING

Routing is especially recommended for trimming workpieces. Always use routers of at least 750 Watts, and a speed of 18 000 to 25 000 rpm is preferred. Bits should be straight fluted preferably two-fluted, carbide-tipped, or high-speed steel, with a diameter of 4 to 12 mm. Always feed counter rotation-wise up to 1.5 m/min, and cool with compressed air only.

Manufacturers of routers:

Geiss Thermoforming, Max Mayer, Pacer Systems Limited

4 SHEARING, BLANKING, PUNCHING & DIE CUTTING


Also surface friction might cause similar discoloration.

Shearing and Punching

Shearing will produce linear straight-edged cuts, while punching and blanking can produce a variety of shapes.

These fabrication methods can be used on Griphen™ Frost sheet in 2 mm. For thicker sheet, routing is preferable to above mentioned techniques. It is important to adjust the blade clearance in relationship to the bed knife. A clearance of approx. 0.025 mm is desirable to avoid a rough edge cut. Cracking and chipping can be reduced by heating the sheet to max 45°C; however, some allowance for hole shrinking due to cooling may be necessary.



page 6

Die Cutting

This is a technique frequently applied to paper. Griphen™ Frost can be die cut up to 2 mm, with steel rule dies

(A ribbon of steel bent to any desired contour and mounted in or around a block of wood). Blades of 0.8-1 mm thickness work well. The steel rule must be sharpened or replaced fairly often.

Symmetric double bevelled blades (15 & 30°) are recommended. For thicknesses above 1.5 mm asymmetric blades should be used. To obtain straight edges, one side bevelled blades under 30° must be used.

Keep the back-up pad (made out of nylon or HDPE high density polyethylene) in good shape and ensure a perfect alignment of the die and the pad to obtain appropriate cuts.

Adequate power in the die press is needed to achieve the desired cut..

The die press tonnage can be calculated using following formula:

F(Tons) = S x t x P/ 10 000

S = Shear strength = 33 (Mpa) t = thickness in mm

P = Perimeter of cut in mm

Manufacturers of shearing, punching & die cutting machines:

Sandt AG

5 DRILLING

Drills designed for plastics are recommended, but standard twist drills for metal will do the job as long as they have not been used on metals before, though they require slower speeds and feed rates to produce a clean hole.

For deep holes, in the edges of thicker gauge sheet for example, cool with compressed air and frequently back out the drill to free chips and prevent melting of them. Never use cutting oils. Like other transparent plastics.

Griphen™ Frost is a notch-sensitive material and cutting threads develop stress points that can create stress crazing or cracking. Always keep a distance from the edge, minimum 1.5 times the diameter of the hole. Be sure drilled holes are smooth with no evidence of cracks or roughness, which can cause breakage when fastening.

Do not use countersunk screws with Griphen™ Frost sheet. ( see mechanical fastening )

Clearance angle

Rake angle

Top angle

Helix angle

Cutting speed

Feed

5 - 15°

0 - 5°

110 - 130°

30°

30 - 60 m/min.

0,1 – 0,6 mm/rev



page 7

6 TAPPING

Be aware that tapping will create notches in the part, which might decrease local impact resistance and stress resistance.

Conventional 4-flute taps can be used for cutting internal threads in plastic sheet when a close fit is required. Such taps, however, have a tendency to generate considerable heat during the tapping operation. A high-speed, 2-flute tap will offer longer life and greater tapping speed than a conventional tap, and provide clearance for chip discharge.

In order to obtain uniform thread, flutes should be ground so that both edges cut simultaneously.

Cutting edges should be 85° from the centre line, giving a rake of minus 5° on the front face of the lands so that the tap will not bind in the hole when it is backed out. It is desirable to have some relief on the sides of threads.

7 MILLING

Standard high-speed milling cutters for metal achieve best results, provided they are sharp (not been used on metal before) when applied on.

Typical parameters are 500 rpm and feed 0.25 mm/rev.

8 LASER CUTTING

Lasers can be used to cut Griphen™ Frost, giving clear edges up to 5 mm thickness. The result of the cut depends on the installation and its parameters. Preliminary cutting-tests are recommended. . Laser power and travel speed must be optimised to minimise ‘whitening’ of the Griphen™ Frost sheet while cutting.

Fumes coming off during cutting might smell unpleasant and therefore it is recommended to use appropriate exhaust systems.

Do not to induce stress into freshly laser cut sheet (e.g. cold brake forming), as breakage might occur.

Therefore it is recommended to anneal the sheet (max 50 °C) or stock it for some time (min 1 week) prior to that specific forming technique.

page 8



Forming

1| Cold forming

· Cold curving

· Cold bending & brake forming

2| Thermoforming

· Hot line bending

· Drape forming

· Vacuum forming

3| Trouble shooting

1 COLD FORMING


Also surface friction might cause similar discoloration. This effect can be reduced by local heating (hot air or flame), but will be very difficult to delete fully.

Cold curving

Griphen™ Frost can be cold curved with a minimum radius of 175 times the gauge thickness for outdoor applications, and 125 times the thickness for indoor applications (Note that when exposed to UV radiation Griphen™

Frost will age similar to PETG sheet). When smaller radii are needed thermoforming is the solution.

Cold bending & brake forming

Due to surface whitening on the bend zone, this technique is not recommended for esthetical reasons.

The alternative is hot line bending.

2 THERMOFORMING

Griphen™ Frost sheet retains its matt surface even when formed with higher draw ratios.

Surface friction has to be reduced to a minimum to avoid local surface whitening. In some cases this whitening can be reduced by locally heating the area with hot air or by means of a flame.

Griphen™ Frost sheet does not need to be pre-dried and can be thermoformed at low temperature (110-

155°C). Sheet temperatures over 160°C may cause blistering and damage the sheet.

The adhesive masking on the Griphen™ Frost sheet has to be removed prior to any thermoforming technique.

Take care while heating the sheet. Heating too fast will result in heat accumulating at the sheet surface and degrade it. Because of its low specific heat, Griphen™ Frost sheet requires only a little energy to be formed.

The most appropriate heaters are infra red heaters. Contact heating and high-frequency heating are not suitable.

Halogen heaters only are suitable for coloured sheet.



page 9

Hot line bending

The Hot Line Bending equipment is a simple IR- or electrical resistance heater, bending-calliper coated with fabric and a clamping device.

To keep the finished part protected, the masking can be removed locally on the bend zone alone. Perform a preliminary test to find out the correct heating time.

The heating time depends on the power of the IR heaters. With one side heating, it takes about 2 min to make a 3 mm sheet weak enough to bend. Thicker sheet need to be heated from both sides. If not available, turn periodically during the heating cycle. Always bend the sheet with the last heated side forming the outside radius.

When Griphen™ Frost softens, remove from heating source, bend, place into calliper and clamp.

Cool slowly to prevent distortion. Keep the part close to the heating device to make it cool down evenly. Once the part is at about 75 °C, it can be placed in a fixing device and cool down in the air.

Manufacturers of hot line bending machines:

R Clarke & Company Ltd, EFC, Shannon BV

Drape forming

Uni-axial bent parts can be achieved by drape forming. The mould can be made out of wood or aluminium covered with felt. Slight pressure (with soft gloves or cloth, e.g. linen) is sufficient to drape the Griphen™

Frost sheet over a positive mould.

Remove standard masking before putting into an IR oven to be heated. Preferably the sheet should be clamped in a frame, as placing it on a bed might mark the sheet. The sheet temperature should be about

130°C to achieve easy forming. Place sheet on the mould immediately after heating; therefore minimise distance between mould and oven. Cool in surrounding air, but take care for drafts which could cause distortion of, and stress in the finished parts.

Note that as the sheet is not framed during the process it will shrink during the heating process (for thin sheet up to 6% in extrusion direction).

Vacuum forming

Griphen™ Frost sheet retains its matt surface even when formed with higher draw ratios.

Surface friction has to be reduced to a minimum to avoid local surface whitening. In some cases this whitening can be reduced by locally heating the area with hot air or by means of a flame.

Because of its perfect flow properties, Griphen™ Frost sheet, allows you to make the most complex finished parts. Draw ratios of 4:1 can be achieved. Standard available vacuum forming machines, preferably with a sandwich heating system, can be used to forem. Griphen™ Frost requires a minimum vacuum of

500 mm Hg (0,66 atm or 0,066 MPa), but higher vacuum is preferred.

Moulds

Depending on series to be produced and the required finish of the parts, one can use different mould materials. Be aware that the mould material affects both cooling time and finish of the formed parts.



page 10

Design moulds with such roundings that the Griphen™ Frost can slip over; however, friction can cause local whitening.

For a good evacuation of air, it is important to make an optimum number holes in the right places. Inadequately placed holes might cause optical defects on the formed parts. This may occur especially on parts with large flat surfaces.

A mould temperature of 50-55°C gives best results. To achieve a perfect optical finish, it is recommended to use temperature-controlled moulds.

Negative and positive mouldings

Negative moulds result in finished parts with a thin bottom and thick walls, whilst positive moulds result in parts with a thick bottom and thin walls. Depending on the application, either a positive or a negative mould should be built.

For better external finish use negative moulds which show more detail.

Heating

Remove standard protection masking prior to thermoforming, and blow off the sheet and mould with ionised pressurised air.

When clamped on 2 sides only (e.g. in automatic feeders) be informed that the free side might shrink (see drape forming). Therefore 4 side clamping is preferred. If a heating profile is available, it is recommended to adjust it as such that when pre-blown, the sheet forms the same shape as the mould. That way the best thickness spread is obtained.

Griphen™ Frost sheet requires only 155°C to form even the most complex structures. One side heating is not recommended for sheets of 3 mm and above. To prevent surface degradation, avoid fast heating. The sheet can only absorb part of the IR radiation and accumulation of heat will damage the sheet and embrittle the formed part.

Cooling the formed part

Cool with compressed air; possibly with water mist (avoid droplets as they might cause marking). Let the part stiffen sufficiently and take it from the mould. Shrinkage of Griphen™ Frost is about 0.4%.

Using positive moulds, shrinkage might cause removal problems. Take care to remove before the part shrinks on the mould. Do not cool too fast, because the generated stresses may result in cracking. If necessary, post-forming relaxation can be done at 65-75°C.

Take care when stacking formed parts, as surface friction can cause local whitening.

Manufacturers of vacuum forming machines:

Adolf Illig Maschinenbau GmbH & Co KG, Brown Machinery LLC, Formech Ltd, Jürgen Schönwolff, Maschinenfabrik

Georg Geiss, Meaf Machines BV, Meico srl – T.S.T., Kiefel GmbH, Reichel GmbH, Shelley Thermoformers

International Ltd.

page 11



Free Forming

These techniques are utilized in forming dome shapes. Free blown billow forming uses air pressure while free drawing uses a vacuum.

The sheet is heated until a sag is formed. An optical switch and/or a micro-switch are coupled with the pressure

(vacuum).The initial pressure (vacuum) is high (2,8 MPa or more) and is lowered towards the end of the forming cycle.

The pressure (vacuum) is held until the sheet temperature reaches 75°C and the forming is able to be removed. Here will be no mark-off as no moulds are used, but dirt or oil in compressed air may cause marks on the sheet.

Plug-assist vacuum forming

Corner or periphery thinning of box-shaped articles can be prevented by use of a plug-assist to mechanically stretch and pull additional plastic material into the female cavity. The plug should be 10 to 20 % smaller than the mould and should be heated to ca 110-130°C. Once the plug has forced the hot sheet into the mould cavity, air is drawn from the mould to form the part.

Other methods

Other thermofoming methods are combinations of above mentioned ones.

Plug-assist vacuum forming and plug-assist pressure allow deep drawing and permit shorter cooling cycles and good wall thickness control. Both processes require close temperature control and are more complex than straight vacuum forming. High pressure forming (HPF) and Twin sheet forming (TSF) are two advanced methods which for small to average series can compete with injection moulding and blow moulding.

High Pressure Forming

Using a negative mould, the atmospheric air pressure that spreads the softened sheet over the mould, is increased by

Twin Sheet Forming

Two heated sheets are brought between two negative moulds. Air pressure in between those sheet is applied while the circumference of the sheet is clamped. An alternative technique forms the upper and lower part separately, and both parts are brought together, the circumference is reheated to obtain fusion of both parts. This technique creates hollow shapes, to obtain light parts with high structural stiffness.

page 12



3 TROUBLESHOOTING

Problem

Crazed or weak parts

Webbing

Reduced or incomplete details

Part sticks on to mould

Mark-off

Surface defects

Unequal parts

Brittle parts

Cracks or breakage

Bubbles in the sheet

Possible cause

sheet too hot mould too cold part removed too late vacuum rate too fast sharp edges sheet surface too small uneven heating mould spacing too small vacuum rate too fast sheet surface too big too small vacuum sheet temperature too low mould too hot part removed too late draft angle too small mould surface too smooth sheet temperature too high edges: masking came off vacuum holes at the wrong place vacuum holes at the wrong place dust on mould or sheet mould/clamp too cold uneven heating/cooling part removed too late overheated parts stresses too high too much heat moisture

Solution

reduce heating increase mould temperature shorten cooling cycle restrict vacuum round corners use bigger sheet check for hot spots or shade spots min. spacing = 2 x depth restrict vacuum clamp-mould spacing < 50 mm check for leaks add vacuum holes increase heating reduce mould temperature remove earlier draft angle should be> 6°

Sand surfaces reduce heating time cut sheet with unprinted masking up redesign vacuum holes redesign vacuum holes clean with compressed air increase pre-heating check for drafts, check heater remove part sooner decrease heating power heat slower on wider area reduce heating pre-dry

HLB DF VF FF

page 13



Bonding and fastening

1 Solvent bonding

2 Adhesive bonding

3 Recommended bonding designs

4 Tape bonding

5 Mechanical fastening

6 Welding

1 SOLVENT BONDING

Use extreme caution when working with solvents: they may be toxic or contain carcinogens. Adequate ventilation is essential. Obtain Safety Data Sheets from the solvent manufacturer.

This technique has been used for years to make displays from acrylic sheet, but can also be used to construct three-dimensional shapes with Griphen™ Frost sheet. To bond small pieces, one can use a hypodermic needle and making sure that the solvent flows throughout the area to be cemented.

Edge dipping is another method used to assemble two flat parts under a 90° angle. The edge of the sheet which is to be bonded, is dipped in the solvent until it becomes soft. Then it is put on the flat sheet under slight pressure.

The jointed articles can be safely placed on a table to dry after the solvent has been applied. Special care should be taken that no air bubbles are left after curing. Both methods depend on smooth edge preparation, pressure and curing.

Applicable solvents

Methylene dichloride

Acetone

Chloroform

Tetrahydrofurane (THF)

Methyl ethyl ketone (MEK)

Trichloroethylene

Cyclohexanone

Boiling point

40,5 °C

56,5 °C

61,1 °C

66 °C

79.7°C

87,0°C

155,0°C

When using solvents it is advisable that the work area be climate controlled with low humidity to minimise joint

‘whitening’. If this is not possible, the addition of 10 % glacial acetic acid (boiling point 116.5 °C) to the solvent or use of a slower curing cement-type bond is suggested. Solvents with a low boiling point, may cause whitening or insufficient softening of the treated surface which results in improper joints.

To prevent early evaporation, use mixtures of the above mentioned solvents or dissolve Griphen™ Frost chips in one of them to increase boiling point.



page 14

Mixture suggestions :

- 42% MEK, 42% Trichloroethylene and 16% Methylene dichloride

- 85% Methylene dichloride, 12% Trichloroethylene and 3% MEK

When using a solvent in which 8% of Griphen™ Frost chips have been dissolved, the curing time is longer, allowing you to adjust the position of the two parts to be bonded, and preventing them from whitening.

To obtain above mentioned solvents contact local chemist or drugstore, or check for specialty chemicals suppliers like www.brenntag.com

2 ADHESIVE BONDING

When working with adhesives, the usual safety and health precautions should be taken and eventual special instructions from the adhesive manufacturer should be observed.

A lot of commercial adhesives have proven their effectiveness for bonding GRIPHEN™FROST. Types, which can be used, are Akrifix™118, Extrufix™, Ruderer™118. Adhesives on polyurethane or acrylic basis give good results. Take into account that stresses in the sheet or parts in combination with solvents or adhesives may cause cracking. For optimum gluing results remove the surface locally. Cut and finish the surfaces to be bonded carefully.

A good alternative is a 2 component polyurethane adhesive, which exists in a clear transparent grade.

Manufacturers of adhesives:

Agomet Klebstoffe GmbH, Bostik Findley B.V., Engineering Chemicals BV, Kömmerling Chemische Fabrik KG,

Loctite Corporation, Lord Corporation (Europe) Ltd., Meco GmbH, National Starch & Chemical NV,

Bison International bv, Permabond, Rectavit NV, Ruderer GmbH, UHU GmbH, Vantico page 15



3 RECOMMENDED BONDING DESIGNS

Joint design, often overlooked, should be such that the bonding area carries the load equally, with the major stresses in tension or shear thereby minimising cleavage and peel stresses. The lap joint is the most frequently encountered joint type when working with relatively thin gauge materials.

Angular connection

Direction of forces Recommended construction

page 16

??



Flat connection


?

T-shape connection


page 17

?



4 TAPE BONDING

Due to its specific matte surface, tape bonding might not give the right results.

Double sided self adhesive tapes, transparent and mostly on an acrylic basis, can be used to make quick fastenings. These tapes are elastic and stick to different materials. They can be quite useful in bonding thin sheet materials to other plastics, glass or metals.

Use following procedure to make proper bondings:

· Bend along the part for more than tape width.

· Clean this zone with a 50% Isopropyl alcohol - water solution.

· Pressing with wooden roller evacuates trapped air and improves strength.

Manufacturers of bonding tapes:

3M Company, MACtac Europe S.A., Scapa Tapes

5 MECHANICAL FASTENING

Due to its high impact resistance, all types of mechanical fastening can be applied, depending on thickness of the

Griphen™ sheet up to 1.5 mm, it can be nailed, stapled or riveted. These kinds of fastening are not recommended for industrial applications.

The best way to fasten Griphen™ is to use screws with a cylindrical head. Never use screws with chamfered heads. They cause stress cracking. Drill holes 0.5 mm larger than the screw. Screws of plastic can always be used. When using metal screws or bolts, use plastic washers (nylon). Metal thumbscrews can be used without washers.

Use galvanised types only.

Never use glue to tighten bolts.

No more than 2 extra twists after turning firm by hand.

Mechanical fastening will produce a stronger part than solvent bonded parts and allows for easier disassembly and cleaning.

6 WELDING

While mechanical fastening and solvent bonding are the most often recommended methods of joining Griphen™ Frost, another alternative is welding.

Ultrasonic welding and spin welding have both proven to be appropriate. High frequency welding is not suited. Contact manufacturers of ultrasonic welding equipment for recommendations on section and joint design.

Manufacturers of ultrasonic welding equipment:

Branson Ultrasonics Corp, Pfaff AG

Also possible is hot air welding, using a welding rod made of PETG or if not available locally also a strip cut from a 3 or

4 mm Griphen™ Frost sheet will work well.

Manufacturers of hot air welding equipment:

Pfaff AG



page 18

Finishing

1 Sanding

2 Polishing

3 Decorating

1 SANDING

The sheet edges can be sanded using both wet and dry systems. Dry sanding can result in gumming as frictional heat build-up is created. Wet sanding gives a smooth finish. In both cases, further finishing in order to restore the gloss will be necessary.

Example : start with 80-grit paper and end with 400 or 600-grit.

2 POLISHING

Polishing is a time consuming activity and should only be applied for smaller series and parts made out of thick gauge sheet. The edges can be polished by different techniques. Keep in mind the specific colour of Griphen™: a glass clear edge will rarely be achieved.

Mechanical polishing

After grinding, surfaces of Griphen™ Frost sheet can be polished in order to obtain a better surface finish. Burnish wheels of cloth or fleece and felt polishing bands, together with a suitable polishing wax, give good results. Keep surface temperature low, in order to a later appearance of fine cracks. Suppliers of mechanical polishing tools:

Suppliers of mechanical polishing tools:

3M, EFC (US)

Diamond polishing

Griphen™ Frost sheet can be diamond polished resulting in an excellent surface quality that does not need further treatment. No pre-grinding step is required, as per step up to 0.5 mm can be removed.

Suppliers of Diamond polishing tools:

Shannon B.V., EFC (US)

Flame polishing

Use a standard propane - or butane torch or a hot nitrogen welder. It is very important to control the distance between the sheet and the heat source. Without proper control, surface whitening or material flow of the Griphen™

Frost might occur.



page 19

nstead of a torch, an electrical hot air device can be used.

As with Acrylics, flame polishing Griphen™ Frost sheet can cause long-term edge cracking. However, with continued practice and by using proper techniques, excellent results can be achieved.

Solvent polishing

The appearance of saw-cut edges can be improved by first sanding them. For smoother, glossy edges, consider solvent polishing with MEK or methylene dichloride. To prevent humidity blush after drying, add a small amount of a slow-drying component such as diacetone alcohol.

Use extreme caution when working with solvents. Adequate ventilation is essential. Follow precautions Safety

Data Sheets from the solvent manufacturer.

3 DECORATING

Flat sheets can be screen printed, tampon printed, hot stamped or decorated with self adhesive films. Vacuum formed parts can be tampon printed or hot stamped.

Other techniques are (spray) painting, laser marking, sand blasting, …

Hot stamping

Griphen™ Frost sheet or formed parts made out of Griphen™ Frost are easily decorated by hot stamping. Decoration can be done on single pieces (vertical stamping or roll-on stamping) upto continuous pieces. Special types can be thermoformed. Typical conditions are:

Die temperature: 190 °C

Pressure: 0.4 N/mm2

Dwell time: 2-3 seconds

Hot stamping foil / tools manufacturers:

Leonhard Kurz GmbH & Co, John T Marshall Ltd

Screen printing

Griphen™ Frost sheet can be printed with conventional printing equipment. In general, printing inks which are compatible with thermoplastic oriented polyesters (PET) work well. Since the ink does not penetrate GRIPHEN™

FROST as it does with paper or fabric, it is subject to abrasion. This problem can be minimised by applying a clear top lacquer over the printing.

All standard Griphen™ Frost sheets have an adhesive polyethylene masking. It is very important to ensure the sheet is clean and free from dust and dirt prior to screening. Use ionized air to remove dust.

Be careful not to exceed 65°C during the cure process.

In case of questions, please consult your ink supplier.

Apollo colours Ltd, Coates Screen Inks GmbH, Coates Screen inks Ltd, Diegel GmbH, Marabuwerke GmbH & Co,

Pröll KG, Ruco Druckfarben, Sericol International, Unico NV



page 20

Cleaning

Griphen™ Frost sheet may be cleaned by using a clean soft sponge and washing with lukewarm water containing a mild soap or a slightly acidic, neutral or slightly alkaline detergent. Then rinse thoroughly with clean water and dry with chamois leather or a moist sponge. A subsequent anti-static treatment is recommended.

Fresh paint splashes, grease, smeared glazing compounds, etc. can be removed before drying by rubbing lightly with isopropyl alcohol on a soft cloth followed by a thorough wash and rinse as described above. Rust stains can be removed with a 10% oxalic acid solution.

Do not use abrasive or highly alkaline cleaners, acetone, benzene, leaded gasoline or carbon tetrachloride on

Griphen™ Frost sheet.

Never scrape with razor-blades or other sharp instruments. Having good electrical insulating properties, Griphen™

Frost sheet is subject to electric static charge and dust attraction. Treatment with an anti-static agent keeps the sheet free from static charge and dust over prolonged periods.

There are some commercially available products which act simultaneously as cleaning agent and anti-static agent.

Before commencing certain operations on Griphen™ Frost sheet such as painting, screen printing or thermoforming, it is recommended that dust particles be blown off first, using an ionised air gun. Dusting with a regular air gun or a cloth only moves the particles rather than removing them.

page 21



Material Properties

Property

Physical Properties

Density

Light transmission (Light source D65, thickness 3 mm)

Refractive index

Unit

g/cm

%

%

3

Value

1.27

-

1.57

0.2

Standard

ISO 1183

ASTM D1003

ISO 489

ISO 62

Mechanical Properties

Tensile strength at yield

Elongation at yield (at break)

Modulus of elasticity

Charpy unnotched impact strength +23°C

Izod notched impact strength +23°C

Izod notched impact strength -30°C

Rockwell hardness

Thermal Properties

Linear coefficient of thermal expansion (23-40°C)

Thermal conductivity ë

Fire Properties

Fire classification according to UL94

National fire standards

Oxygen Index

Electrical Properties

Volume resistivity, dry

Surface resistivity, dry

Dielectric strength, dry (1 mm)

Dielectric constant, dry 1 MHz

N/mm

%

N/mm

2 kJ/m

2 kJ/m

2 kJ/m

2

°C

°C

W/m K

Class

%

Ù kV/mm

2

1

53

40

2200

NB

11,5

4,4

R115

51

68

72

0,19

HB

25

10

16

10

15

30

2,4

0,02

ISO 527

ISO 527

ISO 527

ISO 179/2D

ISO 180/1A

ISO 180/1A

ISO 2039-2

ASTM D696

ISO 75

ISO 75

DIN 52612

UL 94

See below(°)

ASTMD2863-77

IEC 60093

IEC 60093

IEC 60243

IEC 60250

IEC 60250

(°) A list of products that have been tested to national fire standards and their respective classification is presented at www.arlaplast.se.

For latest information contact our technical support.

page 22



Usefull addresses

3M Europe

Hermeslaan 7

B-1831 Diegem

Tel. +32-2-722 45 00

Fax +32-2-722 45 11 [email protected]

www.3m.com

Brown Machinery LLC

330 N. Ross Street

Beaverton

USA-48612 MI

Tel. +1-989-435 77 41

Fax +1-989-435 28 21

[email protected]

www.brown-machine.com

Adolf Illig Maschinenbau GmbH & Co KG

Robert Boschstrasse 10

D-74081 Heilbronn

Tel. +49-7131-50 50


www.illig.de

Coates Screen Inks GmbH

Wiederholdplatz 1

D-90459 Nürnberg

Tel. +49-911-64 220

Fax. +49-911-64 222 00 [email protected]

www.coates.com

Apollo colours Ltd

127 Nathan way

West Thamesmead business park

UK-SE28 0AB London

Tel. +44-20-88 54 00 17

Fax +44-20-83 16 69 56

[email protected]

www.apollocolours.co.uk

Coates Screen inks Ltd

Cray avenue

St. Mary Cray

Orpington

UK-BR5 3TT Kent

Tel. +44-1689-89 96 66

Fax +44-1689-87 82 62

[email protected]

www.coates.com

Bostik Findley B.V.

Postbus 303

NL-5201 AH 's-Hertogenbosch

De Voerman 8

NL-5215 MH 's-Hertogenbosch

Tel. +31-73-624 42 44

Fax +31-73-624 43 44 [email protected] www.bostikfindley.nl

C.R Clarke & Company Ltd

Betws Industrial Park

Soundry Rd

UK-SA18 2LS Carmarthenshire

Tel. +44/1269 590 530

Fax +44/1269 590 540 [email protected]

www.crclarke.co.uk

Branson ultrasonics

Applied Technologies Group

41 Eagle Rd.

Danbury, CT 06813-1961

Tel. +1-203-796 04 00


www.branson-plasticsjoin.com



page 23

Diegel GmbH

Ernst-Diegel-Straße 1

D-36 291 Alsfeld

Tel. +49-6631 78 50

Fax +49-6631 78 585 [email protected]

http://www.diegel.de

Geiss Thermofoming

Industriestrasse 2

D-96 143 Sesslach

Tel.+49-95-69 92 21 0

Fax+49-95-69 92 21 20 [email protected]

www.geiss-ttt.com

Dymax Europe GmbH

Trakehner Strasse 3

D-60441 Frankfurt am Main

Tel.+49-6971-65 20 58

Fax+49-6971-65 38 30 [email protected]

www.dymax.com

Haubold Technik

Industriestraße 8

D-69 509 Mörlenbach

Tel. +49-6209-88 19

Fax +49-6209-53 53

[email protected]

www.haubold-technik.de

Edge Finisher Company

16 Stony Hill Road,

USA-06801 Bethel CT

Tel. +1-800-625-5863

Fax +1-203-796-7924 [email protected]

www.edgefinisher.com

Henkel Loctite Corporation

Adresses: see website

Email: see website www.loctite-europe.com

Engineering Chemicals BV

Van Andelstraat 7

NL-4650 AB Steenbergen

Tel. ++31-1675-669 84

Fax ++31-1675-611 18 [email protected]

www.e-chem.nl

John T Marshall Ltd

Canonbury Works

Dove Road, Essex Road

UK-N1 3LY London

Tel. +44-20-7226 7957

Fax +44-20-7704 9885 [email protected]

www.johntmarshall.co.uk

Formech Ltd.

Unit 4

Thrales end farm/lane

Harpenden

UK-AL5 3NS Hertfordshire

Tel +44-1582-46 97 97


www.formech.com

Jürgen Schönwolff

Reparaturtechnik, Apparatebau

Solterbergstraße 30

D-32602 Vlotho

Tel. +49-5228-549


www.schoenwolff.de

Kiefel GmbH

Industriestraße 17-19

D-83 395 Freilassing

Tel. +49-8654-78 0


www.kiefel.de



page 24

Kömmerling Chemische Fabrik KG

Adresses : see website

Email: see website www.kömmerling.de

Leonhard Kurz GmbH & Co

Schwabacher Straße 482

D-90 709 Fürth/Bay

Tel. +49-911-714 10


www.kurz.de

Lord Corporation (Europe) Ltd.

Chemical Products Division

Stretford Motorway Estate

Barton Dock Road, Stretford

UK-M32 0ZH Manchester

Tel. +44-161-8658048

Fax +44-161-8650096 [email protected]

www.lordadhesives.com

MACtac Europe S.A.

Boulevard Kennedy

B-7060 Soignies

Tel. +32-67-34 62 11


www.mactac-europe.com

Max Mayer

Maschinenbau GmbH - Werk I

Postfach 80 13

Flurstraße 34

D-89 218 Neu-Ulm

Tel. +49-730 88 130

Fax +49-730 88 133 10 [email protected]

www.maka.com

Marabuwerke GmbH & Co

Aspergestraße 4

D-71 730 Tamm

Tel. +49-7141 6910

Fax +49-7141 691147 [email protected]

www.marabu.de

Meaf Machines BV

Industrieweg 10

Postbus 98

NL-4401 LB Yerseke

Tel. +31/113 57 14 95

Fax +31/113 57 12 56 [email protected]

www.meaf.nl/sitemap

Meco GmbH

Radolfzellerstraße 56

D-78473 Allensbach

Tel. +49-7533-16 11


www.meco-online.de

Meico srl – T.S.T.

Via della Giardina 8

I-20052 Monza (MI)

Tel. +39/39 27061

Fax +39/39 2706235 [email protected]

www.meico.it

National Starch & Chemical

Adresses : see website

Email: see website www.nationalstarch.com

Pacer Systems Limited

Gauntley Street

UK-NG7 5HF Nottingham

Tel. +44-1159-88 77 770

Fax +44-1159-88 77 88

[email protected]

www.pacersystems.co.uk



page 25

Bison international

Dr. A.F. Philipsstraat 9

NL-4462 EW Goes

Tel. +31-113-24 82 48


www.bison.net

Rectavit NV

Anton Catriestraat 39

B-9031 Drongen

Tel. +32-92-26 89 41


www.rectavit.be

Permabond

Woodside Road, Eastleigh

UK-SO50 4EX Hants

Tel. +44-2380-629 628


www.permabond.com

Reichel GmbH

Mühle 1

D-55 270 Bubenheim

Tel. +49/6130 92030


www.reibu.de

Pfaff AG

Postfach 3020

Königstraße 154

D-67 653 Kaiserslautern

Tel. +49-631 2000

Fax +49-631 17202 [email protected]

www.pfaff-industrial.com

Ruco Druckfarben

Lorsbacher straße 28

D-65 817 Eppstein

Tel. +49-6198 30 40

Fax +49-6198 32 288 [email protected]

www.ruco.de

Polar-Mohr

Maschinenvertriebsgesellschaft GmbH&Co.KG

Hattersheimer Straße 25

D-65719 Hofheim

Tel. +49-6192-204-0

Fax +49-6192-22193 [email protected]

www.polar-mohr.de

Ruderer

Harthauser Strasse 2

D-85604 Zorneding

Tel. +49-8106-24 210


www.ruderer.de

Pröll KG

Treuchtlinger Straße 29

D-91 781 Weißenburg i. Bay.

Tel. +49-91419060

Fax +49-914190649 [email protected]

www.proell.de

Sandt AG

Lemberger Straße 82

D-66 932 Pirmasens

Tel. +49-6331-71 30

Fax +49-6331-71 31 43 www.schoen-sandt.de

Scapa Tapes Europe

Holland Street

Denton

UK-M34 3GH Manchester

Tel. +44-1613-36 44 33

Fax +44-1613-35 01 04 www.scapa.com



page 26

Sericol International

Pysons Road

Broadstairs

UK-CT10 2LE Kent

Tel. +44/1843 866668


www.sericol.co.uk

Shannon BV

Turfschipper 11-13

NL-2292 JC Wateringen

Tel. +31/174 225 240

Fax +31/174 225 249 [email protected]

www.shannon.nl

Shelley Thermoformers International Ltd.

Stonehill

Stukeley Meadows Industrial Estate

UK-PE29 6DR Huntingdon, Cambridgeshire

Tel. +44-1480-45 36 51


www.cannon.com

UHU GmbH & Co. KG

Herrmannstrasse 7

D-77815 Bühl/Baden

Tel. +49-7223-28 40 [email protected]

www.uhu.de

Unico NV

Essenestraat 20

B-1740 Ternat

Tel. +32-2-582 16 90


www.unico.be

Vantico

Adresses: see website

Email: see website www.adhesives.vantico.com



page 27

Technical Manual

Technical Manual

Transparent PETG sheets

Griphen™ Frost

All information herein described is valid for both Griphen™ and

Griphen™ UV, unless stated otherwise.

CONTENTS OF THIS MANUAL

Chemical Resistance

Fabricating

1 General

2 Sawing

1 GENERAL

2 SAWING

Trouble shooting

3 ROUTING

4 SHEARING, BLANKING, PUNCHING & DIE CUTTING

Shearing and Punching

Die Cutting

5 DRILLING

6 TAPPING

7 MILLING

8 LASER CUTTING

Forming

1| Cold forming

2| Thermoforming

1 COLD FORMING

Cold curving

Cold bending & brake forming

2 THERMOFORMING

Hot line bending

Drape forming

Vacuum forming

Moulds

Free Forming

Plug-assist vacuum forming

Other methods

3 TROUBLESHOOTING

Bonding and fastening

1 Solvent bonding

1 SOLVENT BONDING

2 ADHESIVE BONDING

3 RECOMMENDED BONDING DESIGNS

4 TAPE BONDING

5 MECHANICAL FASTENING

6 WELDING

Finishing

1 Sanding

2 Polishing

1 SANDING

2 POLISHING

Mechanical polishing

Diamond polishing

Flame polishing

Solvent polishing

3 DECORATING

Hot stamping

Screen printing

Cleaning

Material Properties

Usefull addresses

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