This article takes an in-depth look at plastic channels.
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Plastic channels are plastic products that have linear extruded profiles. They have a constant cross-sectional shape across their axis. They are long and narrow structures, and their depth is relatively short. These products serve a variety of functions and uses. They are widely used as a trim edging to cover rough surfaces and give a smooth and decorative finish. They can also function as a connector, sealant, insulator, panel, guide, and structural material. They are widely used as a building, construction, and electronic appliance material. The common plastic channel profiles available are U-, H-, J-, C-, and L-channels; customers can request manufacturers to produce plastic channels with custom shapes and dimensions that fit their needs and applications. The plastic extrusion process manufactures 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 plastics used in manufacturing plastic channels are the following:
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 the synthesis of PVC to produce flexible PVC; flexible PVCs have a clearer appearance, rubber-like properties, and enhanced flexibility. Their hardness can range from rubbery soft to semi-rigid. Flexible PVCs are used as cushioning structures and flexible tubing. Unplasticized or rigid PVCs, on the other hand, have higher impact resistance, strength, dimensional stability and can be made into simple shapes.
CPVC is produced by further chlorination of the PVC resin. The additional chlorine gives PVC enhanced durability, chemical stability, and flame retardancy. CPVC has higher temperature resistance than PVC.
ABS is an opaque and amorphous thermoplastic consisting of acrylonitrile, butadiene, and styrene. This material has high impact resistance, toughness, and rigidity. It has good chemical resistance and can withstand aromatic compounds. ABS has a low melting temperature; hence, ABS resins require less thermal energy during molding and extrusion processes, making ABS channels cheaper to produce and inexpensive. However, their lower melting temperatures also make them undesirable in high temperature and outdoor applications. They can be glued by methane-based cement or medium viscosity PVA glue. ABS channels are used in architectural, model railway, and engineering projects.
HIPS is a low-cost, rigid, and tough thermoplastic. It has an amorphous structure and a low melting point. It is lightweight and flexible but produces rigid and impact-resistant plastic profile extrusions. It is easy to thermoform or extrude and fabricate. It also has an attractive and glossy finish. The anti-static properties of HIPS make it suitable as connectors and electronics packaging material. HIPS are also used in automotive, construction, and material handling components.
Green RoHS Vinyl is a plastic material compliant with EU RoHS and REACH Vinyl standards to reduce hazardous substances. The polymer is derived from 57% seawater, and its production requires less energy consumption. It is 100% recyclable. This material contains 80% fewer VOCs than other types of polymers to meet most indoor air quality standards. It does not contain phthalate plasticizers and heavy metals; instead, this material uses renewable organically renewable plasticizers and stabilizers. Hence, this material is safe for infants and children’s products. It does not induce congenital disabilities, cancer, and harm in the reproductive system.
Polyethylene is one of the most widely used plastics in the world. It is an economical material ideal for plastic profile extrusion. It has good chemical resistance and electrical insulation properties. There are several types of polyethylene used in plastic channel production:
Polypropylene is also one of the most used plastics. It is also economical material and can be extruded into several shapes with ease. It is more rigid than polyethylene. It is lightweight, has good chemical resistance, and has a relatively high service temperature. It is commonly used as an edge trim and protector for wires and cables.
TPE is a class of engineered materials that exhibit high elasticity and can easily extrude into custom shapes like other thermoplastics. TPEs possess rubber-like characteristics, and they have a wide range of hardness which can be measured by a Shore durometer scale. Unlike rubber, TPEs use physical cross-linking, which can be reversed by heating, making them highly recyclable without affecting their mechanical properties. The types of TPEs are polyether block amide, copolyester, thermoplastic urethane, polyolefin elastomer, cross-linked TPE, and styrenic block copolymers. TPEs are used in the automotive, construction, and electronics industry.
TPU is a type of TPE that has characteristics of both plastics and rubbers. It is a high-performance polymer that has high tensile strength, durability, flexibility, elasticity, thermal stability, and load-bearing capacity. It has good UV and chemical resistance and is compatible with oils, greases, and solvents. It also has good abrasion resistance. It is breathable and ergonomic; hence it can be used as an edge trim for chairs and tables and as a material for sportswear and footwear. There are flame retardant TPU grades that can be used to protect cables, wires, and electronic components.
Polycarbonate is an amorphous and transparent thermoplastic that has good impact resistance, dimensional stability, abrasion resistance, and electrical insulation. It possesses flame retardant properties, and it has excellent optical properties comparable to glass. It has good chemical resistance that can withstand diluted acids and alcohols. It is moderately resistant to oils and greases; however, it can be attacked by alkalis and halogenated hydrocarbons. Polycarbonates are used in automotive, medical, construction, architectural, and electrical applications.
Butyrate is commonly known as cellulose acetate butyrate (CAB). It is derived from cellulose by chemical modification using butyric and acetic acids through the Viscose process. This modification also makes cellulose a thermoplastic material. Butyrate is a transparent and rigid plastic with high dimensional stability and impact resistance. They are strong, flexible, durable, resistant to UV and most chemicals, and have low moisture absorption. They are easy to process and decorate; it has an attractive and glossy appearance. Butyrate is used as a tubing material, decorative trim, panels for illuminated signs, bathroom fittings, and others.
An extrusion process manufactures plastic channels. Plastic extrusion produces webs of plastic channels with consistent cross-sections continuously, making it a suitable manufacturing method for large quantities of plastic channels.
Plastic extrusion is a continuous and high-volume manufacturing process in which a thermoplastic resin (in powder, pellet, or granule form) is homogeneously melted and then forced into a shaping die by pressure. The hole on the shaping die plate contains the final shape and thickness of the plastic channel. The extruded product is called an extrudate. Plastic extrusion is commonly performed in 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 it passes through the shaping die, the molten resin is filtered by a screen supported by breaker plates to remove contaminants and foreign material that could clog the hole of the shaping die. The breaker plates also convert the spiral flow of the resin into the straight-line flow. The resistance to the resin flow offered by the breaker plates creates back pressure which helps in the mixing and uniform melting of the resin.
The molten resin then passes through the shaping die. The shaping die is a metal plate with a hole that resembles the profile of the plastic channel to be produced. As the melt passes through the other side of the plate, it is formed to its desired shape. The plastic extruder continuously produces a web of plastic channels until no resin is left inside the barrel.
The web is then pulled from the extruder and is cut into individual plastic channels. Finally, the plastic channels will then undergo inspection, quality checking, and packaging.
Coextrusion is sometimes utilized to generate plastic channels consisting of layers made from a different polymer material. Each distinct polymer is fed and melted separately on different extruders; hence, the flow of each individual polymer can be controlled independently since the resin is not blended. The molten resins of the different polymers are injected into a single die to create multi-layered plastic channels. Multi-layered plastic channels offer additional strength and flexibility. Coextrusion is more cost-efficient than the lamination process, which involves molding and fastening individual plastic layers.
The following products are applications of plastic channels:
Edge trims are used to cover sharp and rough edges of appliances and furniture to increase safety and ergonomics. It protects the underlying material and mounted devices on its edges (e.g., cables). They also provide additional aesthetic value. They can be made from a variety of flexible polymeric materials. A metal core is typically present in edge trims to increase its ability to clamp onto edges.
Edge trims can cover edges such as wood, metal sheets, and ceramics. They are used in automobile seats, windows, tables, ceilings, computer cabinets, shelves, machinery guards, and other 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 are structures that serve a variety of purposes. They can be used as a dust cover, panel holder, price tag moldings, and others. Plastic rails are made from rigid materials such as UHMWPE, ABS, PP, and rigid PVC.
Price tag moldings are commonly seen in stores, groceries, and warehouses. They promote and increase the organization of shelved products effectively.
A cable raceway is an enclosed channel that supports, routes, and organizes electrical wiring. It provides a physical pathway for wires and cables. It protects the cables from heat, weathering, and abrasion and conceals them to eliminate safety hazards so that spaces appear neat and organized. It can be used indoors and outdoors and can be mounted on desks, tables, walls, floors, ceilings, and poles. It can be readily installed by means of a self-adhesive backing and does not require special tools during installation.
Latching raceways are popular in residential spaces. They have one-piece construction; one side acts as a hinge while the opposite side acts as a latch which closes the conduit and provides access to the wiring. They commonly have rectangular profiles. The pathway of electrical wiring can be rerouted using compatible tees and elbows.
Slotted cable raceways have wiring slots on their sides. The purpose of these slots is to provide openings for wires in the middle of the raceway in order to connect them conveniently to certain electronic devices or equipment. Slotted cable raceways are useful in branching electrical lines in order to supply power in different areas of residential or commercial space.
J-Channel cable raceways are installed in the back or underside of tables and desks to organize cables and wires.
Corner ducts have a profile shaped like a quarter of a circle. They hide cables and wires on wall corners between the ceiling or the floor. They can mimic the look of crown moldings, which increases aesthetic value.
Wire guards are frequently used outdoors. They are usually mounted on poles and floors, which protect large electrical and communications wiring from the environment. They are typically made from high-impact PVC. Wire guards can be flanged or unflanged. Flanged wire guards have extended lip which lies flat on installation surface and predrilled holes for fastening. Clamps or straps usually install unflanged wire guards. Wire guards do not use self-adhesive backing for installation. The ends of the wire guard may be flared to connect two raceways.
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