| HS Code | 546845 |
| Product Name | Winlite PFVS 0.76 mm |
| Material | Polyvinyl Butyral (PVB) |
| Form | Roll |
| Color | Clear |
| Application | Interlayer for laminated safety glass |
As an accredited Winlite PFVS 0.76 mm factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | Winlite PFVS 0.76 mm is supplied in a sealed carton containing one 30 m roll, individually wrapped for protection. |
| Container Loading (20′ FCL) | 20′ FCL container loaded with Winlite PFVS 0.76 mm, securely packed, ventilated, and stabilized for safe chemical transport. |
| Shipping | Winlite PFVS 0.76 mm is shipped as securely stacked sheets on wooden pallets, wrapped in protective film to prevent scratches and moisture ingress. Standard dry-freight transport is suitable; avoid excessive heat or direct sunlight. Handle with care to prevent edge damage, and keep pallets upright during transit. |
| Storage | Store Winlite PFVS 0.76 mm in its original packaging in a cool, dry, well-ventilated area. Protect from direct sunlight, UV light, moisture, and heat sources. Maintain temperature between 5–30°C and relative humidity below 60%. Keep rolls flat, avoid heavy stacking, and store away from incompatible chemicals or ignition sources. Use within the stated shelf life. |
| Shelf Life | Shelf life is typically 12 months from manufacture when stored unopened in a cool, dry place, away from sunlight. |
Sheet flatness and surface energy control on screen-printing lines handling 0.76 mm expanded PVC are governed less by press speed than by the corona treatment window and ink film weight. The sheet is specified with a surface roughness Ra below 0.8 μm and is passed through a corona discharge unit immediately before ink deposition; surface energy is raised to not less than 40 mN/m as measured by DIN EN 828:2016, because low-viscosity UV inkjet sets lose adhesion below 38 mN/m. UV-curable inks are deposited at 10–18 g/m² wet film weight, with an amine-functional acrylate adhesion promoter added at 0.5–1.5 wt% when corona dwell time is below 2 s. Screen-printed lines using 120–150 thread/cm mesh deposit solvent-based vinyl ink at 5–8 g/m² wet weight, and a retarder is added at 1–3 wt% of ink weight to prevent in-screen drying on runs exceeding 6 h. Cross-hatch adhesion is validated according to ASTM D3359-17 after conditioning at 23 °C ± 2 °C and 50% ± 5% relative humidity for 24 h. Flame performance for point-of-sale graphics in public interior spaces is usually evaluated under EN 13501-1, with Euroclass B-s2,d0 or C-s2,d0 applied to the printed composite rather than the bare sheet because the ink film alters flame particle formation. Terminal products include shelf-edge strips, free-standing retail display panels, exhibition stand infills, and window graphics panels where the 0.76 mm gauge cuts weight relative to solid PVC while retaining sufficient screw-holding strength for perimeter framing.
Vacuum forming of 0.76 mm expanded PVC is limited not by gauge but by the difference between surface and core temperatures during the heating cycle. The sheet is heated in a single-station vacuum former with ceramic infrared emitters arranged 60–80 mm from the sheet surface until the core reaches 95–110 °C; if the surface exceeds 125 °C while the core remains below 90 °C, the foam structure collapses and edge delamination occurs at draw ratios above 2.0:1. The effective core-temperature window for uniform forming is ≤ ±5 °C on single-station machines. A draw ratio up to 3:1 is possible only when heating is staged for 25–40 s per side and a cooling-air burst of 5–8 s is applied before final forming. Regrind addition at 10–20 wt% is permitted in the extruder feed for non-appearance parts; for automotive interior trim and appliance housing face layers, regrind is limited to 0–10 wt% and dried to below 0.1% moisture before blending. Automotive compliance references FMVSS 302 and ISO 3795:1989 horizontal burn performance, with a rate below 100 mm/min required for cabin-facing parts. Electrical appliance enclosures are additionally evaluated by glow-wire testing under IEC 60695-2-11 at 650 °C. The production process includes pre-drying at 60–70 °C for 1–2 h if the sheet has been stored above 60% relative humidity, because absorbed surface moisture forms blisters at heating rates above 8 °C/s. Finished parts include vacuum-formed door panel inserts, equipment fascia covers, vehicle console side panels, and blister trays for point-of-sale merchandise.
In appliance and electronics assembly, 0.76 mm closed-cell expanded PVC is converted into flat gaskets, spacer pads, and insulation liners through rotary die-cutting, kiss-cutting, and sheet lamination. The material is specified under ASTM D1056-20 for flexible cellular materials, typically as a low-density closed-cell grade with compression deflection of 34–103 kPa at 25% deflection; published data for this specific configuration is limited and the supplier certificate should confirm the grade. A pressure-sensitive acrylic adhesive is transfer-laminated at 20–30 g/m², with a 0.09 mm densified kraft release liner. When a solvent-based pressure-sensitive adhesive is used, a crosslinker is added at 0.5 wt% of adhesive solids before coating to prevent edge ooze on parts stored above 40 °C. Die-cutting uses steel-rule dies with a kiss-cut depth tolerance of ±0.05 mm on a flatbed press running at 30–60 strokes/min; clearances below 0.05 mm cause foam compression set, while clearances above 0.12 mm produce burrs that contaminate electrical contacts. Compliance for electrical isolation assemblies includes IEC 60664-1 clearance and creepage verification at the assembly level, not on the sheet alone. Flame retardance may be specified as UL 94 V-0 at 0.76 mm, but this depends on the compound formulation and must be confirmed in the certified UL file. Terminal components include HVAC access-panel gaskets, motor housing dust seals, LCD display spacer pads, and anti-vibration shims in portable electronics.
The 0.76 mm gauge is blanked to ID-1 dimensions in contactless card production under ISO/IEC 7810:2019, where the thickness falls within the 0.68–0.84 mm tolerance without additional face sheets. The sheet is cut into 85.6 mm × 53.98 mm blanks on a high-speed guillotine or rotary die cutter, and sheet-to-sheet thickness variation is held below ±0.03 mm to prevent warp in final card testing. Before printing, the surface is corona-treated and offset-printed with UV-curable inks; the ink formulation contains 3–5% photoinitiator by weight, and a water-based primer is applied at 1.5–2.5 g/m² to anchor UV ink to the foam skin. For magnetic stripe and signature panel attachment, a two-part polyurethane adhesive is coated at 15–20 g/m² and cured at 50 °C for 4 h under 0.5–1.0 N/cm² pressure. Card compliance includes ISO/IEC 10373-1:2020 for physical dimensions, warp, peel strength, and dynamic torsional stress; the sheet itself must meet EU RoHS Directive 2011/65/EU Annex II restrictions on lead, mercury, and cadmium, and REACH Regulation (EC) No 1907/2006 Annex XVII phthalate restrictions for EU market cards. Finished products include transit cards, hotel key cards, employee ID cards with printed graphics, and contactless access cards with embedded antenna.
Roll lamination of the 0.76 mm sheet to corrugated polypropylene, paperboard, or foam-centered boards for rigid point-of-sale structures is controlled by adhesive selection and web tension rather than sheet thickness alone. A moisture-curing polyurethane hot melt is applied at 20–25 g/m² through a slot-die coating head. If a water-based dispersion adhesive is substituted, a polyurethane thickener is added at 0.3–0.6 wt% to maintain coating viscosity at 2,500–4,000 mPa·s at 23 °C and prevent strike-through into the foam surface. The laminating line runs at 15–25 m/min with a nip pressure of 3–5 N/mm, and the foam face must be corona-treated to at least 40 mN/m before adhesive application. Differential expansion between the foam sheet and paperboard substrate is a known failure mode when panels pass through cyclic humidity; warpage is evaluated by moisture conditioning under ASTM D5229/D5229M-20 or by project-specific dimensional tolerance checks after 48 h at 23 °C and 85% relative humidity. Terminal products include shelf-ready POS risers, display headers, game board substrates, and printed book covers where the sheet provides a semi-rigid wipeable face with reduced peeling at the fore-edge.
CNC routing of 0.76 mm expanded PVC for architectural scale models produces a fine electrostatic dust that behaves differently from solid PVC swarf, requiring dust extraction with a minimum air velocity of 20 m/s at the tool head. The sheet is cut on a CNC router with a single-flute upcut bit of 2.0 mm diameter, a spindle speed of 18,000–24,000 rpm, and a feed rate of 1,200–1,800 mm/min. A 5–8 wt% PVC resin solution in cyclohexanone is used as a solvent cement for butt joints; because the solvent attacks the foam core, the cement is applied with a 0.5 mm syringe tip and allowed to flash off for 30–60 s before clamping. For painted surfaces, a waterborne acrylic primer is modified with 1–2 wt% flow additive to prevent pinholes on the foam skin; solvent-based paints containing xylene or toluene are excluded because they degrade the foam core. Mechanical verification for model components references ISO 178:2019 for flexural modulus, and dimensional stability may be checked after 24 h at 80 °C under ISO 2796:1986. Terminal parts include facade model panels, topographic base sheets, interior sectional models, and exhibition presentation boards.
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Winlite PFVS 0.76 mm is a closed-cell free-foam polyvinyl chloride sheet supplied at a nominal thickness of 0.76 mm. The PFVS designation identifies a printable cellular PVC grade intended for low-thickness rigid graphic converting; the dimensional value is nominal and is not the post-conversion tolerance. Standard stock dimensions are commonly 1220 mm × 2440 mm, although converter-specific slitting can alter sheet width. Because published data for this specific product configuration is limited, the material-class ranges that follow should be used for process scoping only and shall be replaced by mill-certificate values for purchased lots. The sheet belongs to a sub-3 mm rigid PVC class used in flatbed digital graphics, screen-printed point-of-sale panels, die-cut display components, and shallow thermoformed parts.
The product differs from solid PVC sheet by the presence of a foamed core between solid cap layers, resulting in a lower apparent density and lower flexural modulus. The cellular structure is closed-cell when produced by free-foam extrusion; surface skins remain printable and smooth. At 0.76 mm, the grade has lower bending stiffness than Celuka boards above 3 mm and lower weight per unit area than solid PVC of equivalent gauge.
Flatness after destacking is governed by residual extrusion stress, moisture equilibration, and platen vacuum. In belt-fed flatbed printers with UV-LED pinning lamps, the leading edge lifts when vacuum plenum pressure falls below the hold-down threshold; operators orient the sheet with the cross-web curl downward and set media thickness to 0.76 mm to maintain printhead clearance. Characteristic density for free-foam PVC sheet is 0.45–0.60 g/cm³ by ISO 1183-1:2019, and flexural modulus is typically 500–1200 MPa by ISO 178:2019. Those values create a lower resistance to bending than solid PVC, so vertical stack storage is avoided.
Surface energy after corona treatment is normally held at 38–42 mN/m when verified by ASTM D2578-23. UV-cure ink adhesion is qualified by cross-cut adhesion testing according to ISO 2409; class 0–1 is expected only when the converter maintains the ink manufacturer’s specified UV dose and substrate temperature. Adhesive failures at the skin-core interface are observed when the surface skin is breached by excessive cutting pressure, so print adhesion should be revalidated after any die-cutting or scoring change.
Preconditioning at 23±2 °C and 50±10 % RH for at least 24 h is applied to stabilise dimensions before flatbed printing or die cutting. Moisture contribution from the closed-cell foam is low; water absorption is generally below 0.5 % by ISO 62:2008, but condensation on cold sheets from storage at RH above 60 % generates print voids.
Corrugated polypropylene has a lower board density and greater bending flexibility, but the PFVS-type substrate offers a smoother print face and tighter thickness tolerance. In flatbed die cutting, the cellular PVC sheet is processed on hydraulic platens with cutting rule heights matched to the sheet gauge. For through-cutting, a rule height of 0.7 mm with a 52° bevel and a 60 Shore D ejection rubber is a practical starting point; for creasing, a channel score depth of 0.4 mm prevents skin fracture while providing a fold line. Edge chipping is observed when blade clearance exceeds 0.05 mm or when the sheet is processed below 15 °C because the PVC matrix loses toughness.
A production-scale bottleneck in this substitution is knife wear from the rigid PVC skin. Converters using flatbed die-cutters report that steel rule intervals require more frequent sharpening than with corrugated polypropylene, especially on long runs exceeding 10,000 impressions. This is because the solid skin layer contains mineral fillers and processing aids that increase abrasion. At 0.76 mm, the die-cut panel does not possess the fluting thickness tolerance of corrugated board; therefore, slotting and folding operations must be adjusted to avoid cracking.
Thermoforming of 0.76 mm cellular PVC requires a narrow surface-temperature band. Ceramic infrared heaters set to deliver a sheet surface temperature of 110–135 °C permit male and female forming. Below 110 °C, mold definition is poor and the sheet may crack at feature corners; above 135 °C, residual blowing agent expansion can produce surface blisters. Mold temperatures are typically held at 40–60 °C. The coefficient of linear thermal expansion for foam PVC is approximately 6.0 × 10⁻⁵ K⁻¹ by ISO 11359-2:2021, so uncontrolled clamp-frame restraint induces directional thinning. Shrinkage should be quantified before forming; a directional free-shrink test at 100 °C for 60 min can reveal whether extrusion orientation exceeds 1.5 % in the machine direction.
The same PFVS chemistry at 3 mm or 5 mm has greater heat capacity and a more forgiving forming window; at 0.76 mm the sheet cools rapidly against the mold surface, so forming speed and plug assistance are critical. Draw ratios above 2:1 with female tooling are not recommended without plug-assisted pre-stretch because corner thinning in the skin layer can exceed 50 %. Published data for this specific configuration is limited, so mold trials should use grid-etch thickness mapping to qualify wall distribution.
Comparative substrate selection is summarised in the following matrix. Corrugated polypropylene is excluded from the matrix because its density and bending behavior are flute-geometry dependent; the table compares the PFVS-class cellular PVC with solid sheet alternatives of equivalent converting gauge.
| Property | Test method | PFVS-class cellular PVC 0.76 mm | Solid PVC sheet | Solid polypropylene sheet | Polystyrene sheet |
|---|---|---|---|---|---|
| Density | ISO 1183-1:2019 | 0.45–0.60 g/cm³ | 1.38–1.45 g/cm³ | 0.90–0.95 g/cm³ | 1.04–1.06 g/cm³ |
| Tensile stress at yield | ASTM D638-14 | 8–15 MPa | 40–55 MPa | 20–35 MPa | 35–55 MPa |
| Flexural modulus | ISO 178:2019 | 500–1200 MPa | 2400–3200 MPa | 1000–1500 MPa | 2700–3500 MPa |
| Shore D hardness | ISO 868:2003 | 45–60 | 75–85 | 60–70 | 75–85 |
| Heat deflection temperature at 0.455 MPa | ASTM D648-18 | 60–70 °C | 70–75 °C | 90–120 °C | 85–95 °C |
| Water absorption | ISO 62:2008 | <0.5 % | <0.2 % | <0.1 % | <0.1 % |
The values in the table are not product-specific acceptance limits. They represent bracketing ranges from industrial free-foam cellular PVC and rigid sheet datasheets. Winlite PFVS lot data must be obtained from the supplier mill certificate before converting conditions are fixed.
Suppliers of cellular PVC sheet for graphic converting typically supply lot-certification data referencing RoHS Directive 2011/65/EU Annex II and REACH Article 33 SVHC disclosure. For the PFVS grade, heat stabilizers are expected to be calcium-zinc or organotin systems; only the supplier declaration can establish whether the formulation is free of lead and cadmium. When end-use fire classification is required, thin cellular PVC sheet may be tested under EN 13501-1; a class of B-s1,d0 is sometimes reported for unprinted PVC foam board, but printed or laminated composites must be classified separately. Continuous service temperature is typically limited to 50–60 °C for free-foam PVC sheet; contact with ketones, esters, and aromatic hydrocarbons must be avoided because these solvents attack PVC. Cleaning should be limited to aqueous systems or a 10 % isopropanol solution at 40 °C.
| Parameter | Test method or regulation | Typical acceptance criterion |
|---|---|---|
| Nominal thickness verification | ISO 4593 | 0.76 mm with supplier tolerance |
| Density | ISO 1183-1:2019 | 0.45–0.60 g/cm³ |
| Surface wetting tension | ASTM D2578-23 | 38–42 mN/m after corona treatment |
| Cross-cut adhesion | ISO 2409 | Class 0–1 after qualified UV cure |
| Water absorption | ISO 62:2008 | <0.5 % by mass |
| Hazardous substances restriction | RoHS Directive 2011/65/EU, Annex II | Lead, cadmium, mercury, hexavalent chromium, PBB, PBDE below stated limits |
| SVHC disclosure | REACH Article 33 | Supplier declaration for Candidate List substances above 0.1 % w/w |
| Reaction to fire | EN 13501-1 | Composite-specific third-party classification required |
Final acceptance of Winlite PFVS 0.76 mm for a specific converting line is contingent on supplier data, not on generic material-class ranges. Process temperatures, vacuum settings, and rule configurations should be locked only after lot-scale trials on the actual flatbed printer, die-cutter, or thermoformer used in production.
