This article delves deeply into the versatile use of plastic channels across various industries.
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Plastic channels are an array of plastic products characterized by linear, extruded profiles having a uniform cross-section along their length. These structures are typically elongated and slender, with relatively shallow depth. They fulfill numerous roles and applications, notably in providing trim edging for covering rough areas and achieving a sleek, decorative finish. Additionally, they may serve as connectors, sealants, insulators, panels, guides, and structural elements. Plastic channels find extensive use in building, construction, and electronic appliances. Commonly seen profiles include U, H, J, C, and L shapes, with manufacturers often accommodating custom requests for unique shapes and specifications tailored to specific needs. The process of plastic extrusion is instrumental in creating these plastic channels.
Thermoplastic materials are used in producing plastic channels. They are a wide class of polymers that can be melted and shaped at elevated temperatures. The extruded part then solidifies upon cooling. The heating and forming of thermoplastic materials can be repeated an indefinite number of times without significant degradation. For thermosetting polymers, on the contrary, heating and molding can never be repeated once the polymeric chains have been cross-linked.
The following plastics are used in manufacturing plastic channels:
PVC is a high-strength, rigid, and durable material. PVCs are known for their high chemical resistance and good electrical insulation properties. They have flame retardant properties attributed to its chlorine content.
PVC is readily available in white powdered or granular form and can be transformed into plastic channels easily. This material can replace traditional materials such as wood, ceramics, metal, and rubber. PVC channels are commonly used as a component for building and architectural materials and as wire and cable protectors.
Plasticizers can be added during PVC synthesis to create flexible PVC, which features a clearer appearance, rubber-like qualities, and increased flexibility. This type of PVC can vary in hardness from soft and rubbery to semi-rigid, and is commonly used for cushioning and flexible tubing. In contrast, unplasticized or rigid PVC offers higher impact resistance, strength, and dimensional stability, and is suited for creating simple shapes.
CPVC is created by further chlorinating PVC resin, which adds extra chlorine to the material. This process enhances the durability, chemical stability, and flame retardancy of CPVC. Additionally, CPVC offers greater temperature resistance compared to standard PVC.
ABS is an opaque, amorphous thermoplastic made from acrylonitrile, butadiene, and styrene. It is known for its high impact resistance, toughness, and rigidity, along with good chemical resistance to aromatic compounds. With a low melting temperature, ABS resins require less thermal energy for molding and extrusion, making ABS channels more affordable to produce. However, their lower melting point limits their suitability for high-temperature and outdoor applications. ABS channels are commonly used in architectural, model railway, and engineering projects and can be bonded with methane-based cement or medium-viscosity PVA glue.
HIPS is a low-cost, rigid, and tough thermoplastic with an amorphous structure and low melting point. It is lightweight and flexible, yet produces rigid and impact-resistant plastic profile extrusions. HIPS is easy to thermoform, extrude, and fabricate, and features an attractive glossy finish. Its anti-static properties make it ideal for connectors and electronics packaging. HIPS is also used in automotive, construction, and material handling components.
Green RoHS Vinyl is a plastic material that meets EU RoHS and REACH standards to minimize hazardous substances. Made from 57% seawater, it requires less energy to produce and is 100% recyclable. With 80% fewer VOCs than other polymers, it adheres to indoor air quality standards. Free from phthalate plasticizers and heavy metals, it uses renewable organic plasticizers and stabilizers, making it safe for infant and children’s products. It does not pose risks of congenital disabilities, cancer, or reproductive harm.
Polyethylene is one of the most commonly used plastics globally, known for its affordability and suitability for plastic profile extrusion. It offers good chemical resistance and electrical insulation properties. Several types of polyethylene are utilized in the production of plastic channels, including:
Polypropylene is another widely used plastic known for its affordability and versatility in extrusion. It is more rigid than polyethylene, yet remains lightweight and offers good chemical resistance. With a relatively high service temperature, polypropylene is commonly used for edge trims and wire and cable protectors.
TPEs (thermoplastic elastomers) are engineered materials known for their high elasticity and ease of extrusion into custom shapes. They exhibit rubber-like properties and can vary in hardness, measured using a Shore durometer scale. Unlike traditional rubber, TPEs use physical cross-linking, which is reversible with heating, allowing for high recyclability without compromising mechanical properties. Common types of TPEs include polyether block amide, copolyester, thermoplastic urethane, polyolefin elastomer, cross-linked TPE, and styrenic block copolymers. TPEs are widely used in the automotive, construction, and electronics industries.
TPU (thermoplastic polyurethane) is a type of TPE that combines the qualities of both plastics and rubbers. Known for its high tensile strength, durability, flexibility, elasticity, and thermal stability, TPU also offers excellent UV and chemical resistance, as well as compatibility with oils, greases, and solvents. Its good abrasion resistance makes it suitable for various applications. TPU is breathable and ergonomic, making it ideal for edge trims on chairs and tables, as well as for sportswear and footwear. Additionally, flame-retardant TPU grades are available for protecting cables, wires, and electronic components.
Polycarbonate is an amorphous, transparent thermoplastic known for its excellent impact resistance, dimensional stability, and abrasion resistance. It offers flame retardant properties and has optical clarity comparable to glass. While it resists diluted acids and alcohols, it is moderately resistant to oils and greases but can be degraded by alkalis and halogenated hydrocarbons. Polycarbonates are widely used in automotive, medical, construction, architectural, and electrical applications.
Butyrate, commonly known as cellulose acetate butyrate (CAB), is derived from cellulose through chemical modification with butyric and acetic acids using the Viscose process. This modification transforms cellulose into a thermoplastic material. Butyrate is a transparent, rigid plastic known for its high dimensional stability and impact resistance. It is strong, flexible, durable, and resistant to UV and most chemicals, with low moisture absorption. Easy to process and decorate, it has an attractive, glossy appearance. Butyrate is used in applications such as tubing, decorative trim, panels for illuminated signs, and bathroom fittings.
Plastic channels are manufactured through an extrusion process, which creates continuous webs of plastic with uniform cross-sections. This method is ideal for producing large quantities of plastic channels efficiently and consistently.
Plastic extrusion is a continuous, high-volume manufacturing process where thermoplastic resin (in powder, pellet, or granule form) is melted and forced through a shaping die under pressure. The die's hole determines the final shape and thickness of the plastic channel. The resulting product is known as an extrudate. This process is typically carried out using a single screw extruder.
Plastic extruders consist of a rotating extruder screw housed in a barrel equipped with heaters that melt the screw. The resin flows in the annular space between the barrel and extruder screw and is gradually heated as it progresses to the shaping die. As the extruder screw rotates, the resin is pushed forward from the feed zone to the metering zone until it is injected into the shaping die. Plastic extruders consist of three zones:
Before the molten resin reaches the shaping die, it is filtered through a screen supported by breaker plates to remove contaminants and foreign materials that could block the die's hole. The breaker plates also convert the resin's spiral flow into a straight-line flow. The resistance from the breaker plates creates back pressure, which aids in the mixing and uniform melting of the resin.
The molten resin then flows through the shaping die, a metal plate with a hole that matches the profile of the desired plastic channel. As the resin exits the die, it takes on the intended shape. The plastic extruder continuously produces a web of plastic channels until all the resin in the barrel is used up.
The web is then pulled from the extruder and cut into individual plastic channels. These channels undergo inspection, quality checking, and packaging before they are ready for distribution.
Coextrusion is used to create plastic channels with multiple layers made from different polymer materials. Each polymer is fed and melted separately in distinct extruders, allowing precise control over the flow of each material since they are not blended. The molten resins are then combined in a single die to form multi-layered plastic channels. This method enhances strength and flexibility while being more cost-efficient compared to lamination, which requires molding and fastening individual plastic layers.
Numerous machines are available in the United States and Canada for producing plastic channels. These machines are vital for various industries, including cable management, automotive, and furniture applications. Below, we highlight some of the leading machines used in this process.
The Conair Extrusion Series, specifically the E Series, is renowned for its versatility and high-quality output. It provides various customization options for plastic channels, including different shapes, sizes, and materials. The E Series machines are noted for their precision, efficient energy use, and user-friendly controls.
Davis-Standard's Thermatic Series extruders stand out for their reliability and consistent performance. They efficiently handle diverse plastic materials, ensuring precise temperature control to uphold product quality. With advanced automation and monitoring systems, these extruders are perfect for high-volume production.
The Milacron T-SERIESâ„¢ T-200 extrusion machine is renowned for its robust construction and outstanding durability. It achieves high production rates and delivers consistent results over time. The T-200 features energy-efficient heating and cooling systems, cutting down on energy consumption and operational costs.
The Battenfeld-Cincinnati SolEX series is renowned for its advanced technology and efficient extrusion process. These machines deliver excellent melt homogeneity, ensuring consistent channel profiles and high product quality. They also feature smart control systems for easy adjustment and optimization of production parameters.
The Coperion ZSK Mc18 extruders are renowned for their exceptional processing capabilities and versatility. Ideal for high-end applications requiring precision and consistency, the ZSK Mc18 series features twin-screw technology, ensuring superior mixing and dispersion of various plastic compounds.
Each manufacturer offers multiple models and series, with specific features varying by model. When choosing a plastic channel production machine, assess your specific needs and consult with manufacturers to find the best fit. Ensure you check the latest models and features, as industry advancements continually evolve.
Plastic channels are used in the following products:
Edge trims are designed to cover sharp and rough edges on appliances and furniture, enhancing safety and ergonomics. They protect underlying materials and mounted devices, such as cables, while adding aesthetic value. Made from various flexible polymeric materials, edge trims often include a metal core to improve their clamping ability.
Edge trims can cover edges on materials like wood, metal sheets, and ceramics. They are commonly used in automobile seats, windows, tables, ceilings, computer cabinets, shelves, machinery guards, and various types of furniture.
Trim seals fill the space between two mating surfaces to provide insulation and airtight sealing for refrigerator doors, freezers, automobile tailgate and passenger doors, compartments, large and insulated containers, and other appliances. Thus, trim seals function as a gasket. Trim seals may consist of coextruded layers of polymers coated with rubber and vinyl to protect them against corrosion, noise, and rattling. They are also reinforced with a metallic core to enhance their gripping onto the edges. Service temperatures, environment (e.g., exposed to moisture, vibration), and grip size and strength are important criteria in selecting trim seals.
Plastic rails serve various functions, including dust covers, panel holders, and price tag moldings. Made from rigid materials like UHMWPE, ABS, PP, and rigid PVC, they offer durability and versatility.
Price tag moldings are commonly used in stores, groceries, and warehouses. They help organize shelved products efficiently and improve product visibility.
A cable raceway is an enclosed channel designed to support, route, and organize electrical wiring. It provides a protective pathway for wires and cables, shielding them from heat, weathering, and abrasion, while concealing them to enhance safety and maintain a tidy appearance. Suitable for both indoor and outdoor use, cable raceways can be mounted on desks, tables, walls, floors, ceilings, and poles. They feature a self-adhesive backing for easy installation without the need for special tools.
Latching raceways are popular in residential settings due to their convenient design. They feature a one-piece construction where one side functions as a hinge and the other as a latch, allowing for easy access to the wiring. Typically with rectangular profiles, these raceways can be modified using compatible tees and elbows to reroute the electrical wiring as needed.
Slotted cable raceways feature wiring slots on their sides, allowing convenient access to wires for connecting electronic devices or equipment. These slots make it easy to branch electrical lines, distributing power across different areas in residential or commercial spaces.
J-Channel cable raceways are typically installed on the back or underside of tables and desks to keep cables and wires neatly organized.
Corner ducts, shaped like a quarter-circle profile, conceal cables and wires at wall corners where the ceiling meets the floor. They can mimic crown moldings, enhancing the aesthetic appeal of the space.
Wire guards, commonly used outdoors, are mounted on poles and floors to protect large electrical and communications wiring from environmental damage. Typically made from high-impact PVC, wire guards come in flanged and unflanged varieties. Flanged wire guards feature an extended lip and predrilled holes for easy fastening, while unflanged wire guards are installed with clamps or straps. Unlike other types, wire guards do not use self-adhesive backing. Their ends may be flared to connect two raceways.
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