HOW OUR FILMS ARE MADE

Introduction to Film Dyeing

Film dyeing is similar to coating in that the film is first coated and then cured in heated ovens. The pigments are impregnated into the polyester film with heat. The film is bathed in dye and then subjected to the elevated temperatures of massive curing ovens. The colour becomes a permanent part of the film and cannot be washed or scraped off. Dyed films are used in both the automotive and flat glass markets. They help minimize reflectivity and provide decorative choice. Dyed films are often used in conjunction with metallized films offering the benefits of both types. The Dyed/Electron Beam and Dyed/Sputter combinations have been the greatest improvement in automotive films in many years. Films are dyed to exacting specifications and are subjected to intensive quality control at all stages of production guaranteeing precision colour and transparency.


Introduction to Vacuum Metallizing

The metallizing industry began in the early 1900s from attempts to improve on the electroplating process. The first applications of metallizing webs, either film or cloth were for decorative packaging. The sputtering method of application was discovered in the late 1800s but only developed and utilized for the production of metallized films in the early 1930s. The currently common aluminum evaporative coating was developed a little later (the late 1930’s). The aluminum coatings were first used in solar control window films because of their extremely high solar control abilities. Technological advances in sputter and electron beam coatings have introduced the additional benefits of high visibility and improved weatherability, while maintaining excellent solar energy control. Window films which contain metallized coatings provide the greatest solar heat reduction available.


Aluminum Evaporative Metallizing

This was the first metallizing process used in solar control films. A crucible containing aluminum is heated until the metal melts and forms a gas cloud. This metal gas is deposited on the film and bonds as soon as it cools. Evaporative coated is limited by the few metals which can be coated in this manner because the crucible must be heated and maintained at a very high temperature. Aluminum is commonly used because it has a relatively low boiling point and is thus easier to control and maintain the temperature required for this process. Aluminum coated films provide exceptional solar control performance. This process is normally used for High Performance Films.


Electron Beam Metallizing

This method of metallizing is similar to evaporative coating in many ways. The main difference is the manner in which the metal is heated and transformed into metal vapor. A beam of high energy electrons is aimed at the source of metal. This energy causes the molecules to vaporize and form a cloud of metal gas. The metal gas bond to the film as it cools. The temperatures obtained on the surface of the metal during this process are much higher than the other methods of coating. Many exotic and precious metals can be coated in this manner.

Electron beam films have higher water vapor transmission rates than sputter coated films. This allows the films to dry much more quickly, especially in high humidity areas. Benefits of electron beam films include high light transmission, low visible light reflection, high solar heat rejection and reduced “hazing” or “fogging” during the curing period that often occurs with sputter coated films.


Sputter Metallizing

Sputter metallizing has brought space age technology to the solar control market. This advanced method of coating uses exotic metals which cannot be evaporative coated. In the sputtering process, an electrically charged gas (usually argon) bombards the metal and knocks molecules loose. These molecules are deposited onto the film and layered side by side providing extremely thin, tight and optically precise coatings. The coating is so tight that the water used during installation of the window films cannot evaporate and thus giving the “hazy” look during the curing period. This “hazy” look will gradually dissipate and give way to a beautiful film. High light transmission, very low visible reflectivity and impressive solar heat control are the trademarks of sputter films.


Corrosion Protected Silver

One window film with superior performance is our Corrosion Protected Silver. This is a sputtered film with a layer of precious metal silver, encapsulated between two layers of a proprietary super alloy to protect it from corrosion. Silver is the best material available for reflecting infrared energy. The special super alloy that protects the silver actually helps to decrease the visible light reflectivity of the silver. The super alloy is so thin there is no serious impact to the silver layers ability to reject heat.

The encapsulating super alloy is virtually impervious to most naturally occurring elements in the environment. While the superior adhesion of this structure will contribute to a slightly longer drying time and the subsequent haze associated with this drying phase. Like other sputtered films, the haze will gradually dissipate revealing a beautiful film with superior performance characteristics. This combination of high visible light transmission and outstanding heat rejection are what make this product one of the stellar performers in the solar control film industry.