28.

0 SURFACE TREATMENT OF PLASTICS PRIOR TO DECORATION

28.1 Introduction:
Some plastic, notably poly olefins and acetals, are high resistant to bonding other
media to themselves. To overcome this deficiency treatments like flame treatment and
electronic treatment such as corona discharge, plasma discharge and chemical
treatments are commonly used.
Flame treatment consists of passing the object through an oxidizing gas flame. The
flame causes an oxidation on the plastic surface and enables the adhesion of inks,
enamels etc.
In corona discharge process high voltage current is used for the oxidation of the
surface. In plasma process air at low pressure through an electric discharge is used to
change the physical, chemical properties of plastics. In chemical treatment products are
dipped in acids resulting in an etched surface which makes it receptive to paint.

28.2 Types of surface treatment

Different types of surface treatment of plastics are screen process printing, hot
stamping, heat transfer decoration, in-mould decoration, two-colour moulding,
electroplating and vacuum metalizing

28.2.1 Screen process printing:

The process of printing through a screen consists of forcing ink or paint through the
interstices of stenciled screen of the required image with a squeeze. The screen
material is often nylon mesh or other synthetic material. Metallic screens such as
stainless steels are also in common use.

28.2.2 Hot stamping:

Hot stamping by the roll leaf process is a method of decorating plastic materials. The
leaf or foil consists of a thermoplastic colour coat applied to an acetate or cellophane
carrier film. When a heated die is pressed against the foil carrier film, the colour coat is
released and adheres to the product placed beneath it.

28.2 3 Heat transfer decoration:

It consists of a paper carrier, a fusible release coat and a thermo plastic ink image. The
ink becomes sticky when heated by a hot platen. When it is pressed against the product
the ink bonds to the surface. Some of the fusible release coat carries over with the ink,
providing the image with a glossy protective coating.

28.2.4 In - mould decoration:

In this method the decoration becomes an integral part of the product making it most
durable and permanent. In compression moulding the mould is loaded with the resin in
the usual manner and closed. After a partial cure it is opened, and the cycle is
proceeded after keeping the foil consisting of a printed cellulose sheet and closing it
again. The foil is fused to the product, during the moulding cycle and becomes a part of
the moulding. For thermo plastic mouldings, the foil or overlay is placed in the cavity
prior to the injections. The overlay is printed in a film of 0.05 - 0.10 mm thick of the
same polymer of that of the product. The ink used to imprint the film must be heat
resistant. The gate location in this case is very important to avoid shifting of the overlay
during injection.
Similar methods can be adopted in decorating blow-moulded products also.
28.2 5 Two-colour moulding:
Two-colour moulding is an injection process where two colours are successively
moulded to create their portion of the finished parts. The shell is moulded first and then
it is transferred to another cavity where the second colour is injected to complete the
product.

28.2 6 Electro plating of plastics.

Plating is done on many plastics to provide a hard wear and corrosion - resistant
surface. Physical properties such as tensile strength, heat deflection temperature etc.
are also enhanced in plated plastics. The surface to be plated is to be properly
conditioned and sensitized. The proper choice of resin for products to be plated is also
very important. Many parts like knobs, light reflectors, name plates etc. are made out of
plastics and plated to give metallic appearance with light weight and corrosion
resistance. Plating is done on many plastics including Phenolic, urea, acetyl. ABS,
polycarbonate etc.

28.2.7 Vacuum metalizing of plastics:

It is process whereby a bright thin film of metal is deposited on the surface of a plastic
moulded product or film while being subjected to a high vacuum. The deposited metal
may be gold, silver or most generally aluminium. Deposition is the result of vaporization
of small clips of the metal to be deposited attached to an electrically heated filament.
When electrical energy is applied to the filament, the clips melt and coat the filament.
Increased energy caused vaporization of this coating, and plating of the product takes
place. The deposition is compiled at high vacuum, in order of 0.5 micron. The thickness
of the resulting coating is about 1 micron.

28.3 Revision

1. Fill in the blanks (1 mark each)

a) ________ by the roll of leaf process is a method of decorating plastic

materials (hot stamping)

b) Plating is done on many plastics to provide a _____, _______ and _____

surface (hard, wear , corrosion resistant)

c) _________ is a process where by a bright thin film of metal is deposited on

the surface of plastic with high vacuum. (vacuum metalizing)

2. Write short notes on (3 marks each)

a) screen printing
b) hot stamping
c) In-mould decoration
d) Two-colour moulding
e) Vacuum metalizing