Powder coating, often referred to as dry paint, is an eco-friendly finishing solution that offers a wide range of colors and design options. As industries continue to evolve, the use of powder coatings has expanded across various fields. With the rapid growth of the aluminum profile industry, powder coatings applied to aluminum have become a specialized segment, gradually replacing traditional coatings such as electrophoretic and fluorocarbon paints. The introduction of transfer technology has further enhanced the visual appeal of aluminum powder coatings, making them more vibrant and diverse.
Aluminum profiles require excellent weather resistance and aesthetic properties, which means surface treatment is essential. Surface treatment for aluminum typically involves organic coatings, including powder coating, fluorocarbon spraying, and wood grain processing. Wood grain processing, in particular, is often applied on top of the powder coating layer. This technique includes two main methods: water transfer printing and thermal transfer printing. Thermal transfer technology was introduced to China in the late 1990s and has seen significant development in recent years. It allows for vivid, multi-layered images that closely resemble printed designs. Unlike traditional printing, thermal transfer uses sublimation ink that turns into gas at high temperatures, enabling a full-color pattern to be transferred in one step without color registration. After sublimation, the image penetrates the powder coating layer by 40 to 60 microns, ensuring durability and preventing peeling, cracking, or fading. The thermal transfer process does not affect the original luster, abrasion resistance, weather resistance, or chemical resistance of the product, as it only serves a decorative purpose.
The thermal transfer industry has developed into a complete system, covering everything from powder coating production, spraying processes, thermal transfer machines, transfer papers, to transfer films. However, the integration of thermal transfer technology with powder coatings also presents new challenges. The powder coating must be compatible with the transfer paper and film to achieve optimal results. Therefore, it is crucial to study the thermal transfer process and develop formulas specifically designed for thermal transfer applications.
The application of thermal transfer technology to aluminum profiles has significantly extended the life of special aluminum powder coatings and enriched their color variety. Many powder coating manufacturers have established dedicated research teams and production lines, contributing positively to the advancement of this technology. Despite these developments, some challenges remain, particularly the issue of paper tearing during the transfer process. During visits to several aluminum powder coating and coating plants, I observed that while the aluminum sheets are well-coated and vacuum-sealed, the tearing stage often becomes a bottleneck. Many workers gather in the tearing and post-cleaning stages, indicating inefficiencies in the process. To improve this, further discussions on formula design, coating techniques, and the quality of pattern ink on wood grain paper are necessary. By addressing these issues, the industry can enhance efficiency and ensure better performance in thermal transfer applications.
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