INNOVATION
KLC commitment is to produce with cleaner, sustainable and innovative processes.
Our R&D team turns curiosity into innovation, working in finding solutions to deliver the greatest possible value for customers.
PVD technology in KLC is following the new trends on continuous innovation on plastic decoration, developing new colours and surface resistant coating, more environmentally friendly.
SURFACE TREATMENTS – PVD
PVD technology in KLC is following the new trends on continuous innovation on plastic decoration, developing new colours and surface resistant coating, more environmentally friendly.
1 – What is PVD?
PVD Coating is the abbreviation of Physical Vapor Deposition. It is a plasma technology for the deposition of a coating in vacuum environment. PVD can add features to all kind of products. It makes a surface smooth, metallic shiny, wear resistant or reduce friction.
1.1 – A bit of history with Aluminum on reflectors
For over 60 years, vacuum coating has been employed to solve problems in industrial production. Coating for optical purposes are another important application. From 1940 to 1944, mirrors were produce by sputtering rhodium. However, aluminum, with a protective layer of SiO2, increasingly replaced rhodium. Since the early 1950s, sputtering has been used for decorative purposes on plastic parts.
Reflectors and backlights of cars were among the first parts in the automotive industry which have been treated with PVD coatings. These reflectors, made from ABS (acrylonitrile butadiene styrene) or PC (polycarbonate), are coated with aluminum since the late 1980s. Initially this was done by evaporating, but, later it was primarily done by sputtering. For corrosion protection purposes, a topcoat of SiO2 is finally applied by a plasma-assisted CVD process.
1.2 – Electroplating vs PVD
PVD brings plenty of advantages over electroplating. It’s a clean and quick process, with extended possibilities for substrate use.
2.1 – Metals
Copper • Aluminum • Chrome • Zirconium • Stainless steel • Titanium • Brass
2.2 – Layers & Thickness
Top Coat UV varnish (optional): It provides protection to the metal layer and increases its performance properties
Metal PVD: Any metal or alloy
Base Coat UV varnish (optional): It seals and improves substrate hardness. It levels eliminating imperfections, improves adhesion and provides brightness
3 – Applications
The applications of vacuum coatings progressed from the simple single-layer coatings used for electrical, optical, and reflecting applications to coatings for corrosion protection and coatings on flexible materials for packaging. Vacuum coatings for display applications, particularly transparent conductive oxides and hard coatings for tools and decorative applications became important new applications.
In the future it is expected that vacuum coatings will continue to play a vital role in developing both existing and new products. An example are the optically variable interference/diffraction films that are fractured and used as pigments in ink to counter counterfeiting.
3.1 – Substrates
PC • PC ABS • ABS • PA • Glass
3.2 – Gloss grades
High Gloss • Gloss • Satin • Matte
3.4 – Color shades
Depending on the evaporated metal (target) and the mixture of reactive gases used during the PVD deposition process, different colors can be produced.
The range includes but not limited to: Brass tones, Gold tones, Black to Grey, Chrome, Copper and Bronze tones. All these finishes are available in a polished, satin or matte finish.
4 – Technical Specifications
Metal: Cr, Ni, Inox, Ti, Cu, CuMx, Zr
Thickness: 1nm till 400nm
OTHER R&D PROJECTS
PVD technology in KLC is following the new trends on continuous innovation on plastic decoration, developing new colours and surface resistant coating, more environmentally friendly.
Ecological Metallization of Plastics
The GREENCoat project aims to develop and improve technological solutions that allow the replacement of the current electrolytic chromium plating process in polymeric thermoplastic components, by the addition deposition method, using the vacuum cathodic deposition technology, hereinafter called PVD (Physical Vapour Deposition).
R&D and production of logos for the automotive industry
The i9LOGO project – aims to develop a technology solution to produce chromed parts which fulfils the applicable requirements of physical and chemical resistance, in particular, logos for automotive industry, non-electrolytic, through PVD – Physical Vapor Deposition, making the metallization process more sustainable, ecological and enhancing new functionalities.
Haptic touchscreens display live front
This project aims to develop a new technological solution which combines, in an integrated manner, the development and the industrialization of a new haptic, anti-scratch and washable solution, obtained from the direct application of an electric circuit printed in the polymeric component. This allows to provide a mirror effect or magnetic shield, night/day, on/off touchscreen display by proximity activation and by pressing buttons which “sink”.