Plastic Channels
Extruded plastics are among the most popular and most useful shapes in the world. Raw material plastics cost very little to obtain, require comparably little energy to manufacture and form, contribute a very small carbon footprint, and offer flexible design options. There is little to not love about plastic extrusions. The linear extruded plastic profiles known as plastic channels are high on the list of frequently utilized plastic extrusions. These versatile shapes can be extruded to any length and can hold, seal, direct, guard, and attach the flow of any liquid their material composition allows.
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Benefits of Plastic Channels
Plastic channels are reliable and incredibly handy plastic extrusions that have been counted upon by manufacturers and consumers alike for many years. For these same number of years, these plastic channels have been made by methods that have changed very little. Now, the plastic extrusion industry is experiencing an exciting infusion of new and innovative technologies. Manufacturers are learning new ways to manipulate plastic products in order to extract more versatility from them. They also focus on developing methods that yield more lightweight but durable products. Finally, these new methods and equipment also focus on green manufacturing. Many companies are, for example, creating and promoting new recycling programs. They are also seeking and implementing new ways to reduce resource and energy usage. Between the historical relevance of plastic extrusions and recent advancements, plastic channels are sure to launch to even greater heights of popularity.
Plastic Channel Extrusion Process
As mentioned, plastic channels are made through the continuous process of plastic extrusion. This process begins with the collection of raw plastic and/or polymer material in a hopper located in suspension above the barrel of an extruder, or extruding machine. After it is collected, the plastic material is released into the barrel of the extruder, where it is compelled into and forced down a conveyance channel via the pressure of the shearing screw of the extruder. This long shearing screw turns, causing a level of friction that in turn produces heat, causing the plastic to become molten. (Some plastic extruders include heating elements in this area to help the plastic melt.) Once the plastic material reaches the end of the conveyance channel, it becomes fully plasticized or molten. Here, it encounters a die, specifically designed and positioned to produce the manufacturers' desired shape. A die, also called a mold (mould) or die mold, is a shaped metal plate with a hole through which the molten plastic material is forced so that it will take on the die’s shape. Once the plastic emerges on the other end of the die, it can officially be called extruded plastic. Said newly extruded plastic must be given a chance to cool and harden before it is touched or further tooled.
Plastic Channel Coextrusion Process
In addition to being produced through standard plastic extrusion, plastic channels can be, and are frequently, fabricated via coextrusion. The process of coextrusion involves forcing two or more different plastic materials through the same die, thus producing a single piece that contains the properties and qualities of more than one material. To get the materials to the die, manufacturers enlist two or more extruders to melt and move the materials separately towards the single die at an even volumetric pace. When they enter the die, they form multiple layers. Because materials are not mixed prior to coextrusion, their individual properties are not altered. Rather, they are retained in the layers of coextruded, homogeneous products. Coextruded plastic channels often combine hard and soft plastic or rubber to create soft sealing channels that feature hard fixtures.
Applications for Plastic Channels
Plastic channels are not just one shape. Rather, they are available in many types of profiles, including, but not limited to, H-channels, U-channels, and J-channels. Plastic channels like these are perfect for use as any number of products, including sealants, window trim, gutters, and connectors. As is the case with window insulation, applications that require multiple internal gaps and chambers for sound and heat insulation require plastic channels on the more complicated end of the spectrum. The applications of plastic channels are nearly endless. In construction industries, plastic channels are used broadly for, in addition to window insulation and trim, applications such as indoor and outdoor trim, outdoor gutters (almost universally known by their channel name: U-channel), outdoor siding, door frame trim, and insulation, bumpers and guards for sharp edges and corners and indoor gutters and drains. Manufacturers make stove door and refrigerator sealants from flexible vinyl and PVC channels in the consumer and commercial appliance industries. Other commercial manufacturers extrude plastic channels into products like point of purchase displays, shelving, guards, drinking straws, curtain rods, partition holders, and picture frames. In addition, automotive manufacturers often use profiled plastic channels to adorn vehicles as interior and exterior bumpers and trim.