Heat Vacuum Application

AerFilm LHR® with Heat Activated Adhesive

Application Guide
August 2010 • Page 1 of 4

Vacuum bagging is a technique primarily used to apply decorative laminate to contoured

panels. Vacuum bagging allows decorative laminates to stretch biaxially. All processing
parameters need to be analyzed and optimized depending on the type of equipment used,
operator and environmental conditions through experimentation.

Equipment Description
The Heat Vacuum Applicator (HVA) consists of the following parts:
1. A radiant heat source (provided by infrared bulbs).
2. A silicone rubber sheet mounted on a frame. (Optimal thickness approximately 60
mils or 1.5mm).
3. A vacuum source.
4. A support fixture—used to support the panel during the application of the decorative
laminate.
5. OPTIONAL: Surge tank (used to provide a fast vacuum pressure)
Controls: Temperature Monitoring System
Vacuum Pressure Gauge

Panel Preparation
1. All damage to the panel should be repaired prior to starting the application process.
2. The substrate panel should be wiped down with a tack rag or isopropyl alcohol.
3. The back side of the decorative should be wiped with a tack rag to remove any dirt,
grease, oil or other contaminants.

Procedure
1. The support fixture should be centrally positioned on the vacuum plate. It is typically
constructed using a heat-resistant, two-component epoxy.
2. Vent holes must be drilled in all recess areas of the panel to ensure adequate vacuum
pressure during the application process. Typically, a No. 72 (0.025”) drill bit is used to
provide adequate vacuum pressure, but not visible after application.
3. It is recommended that a primer adhesive be applied to all recesses on the panel. A
common primer used is Bostik 7132 with Boscodur #24T curing additive. This adhesive
can be thinned by using a solvent such as MEK to aid in the application, as well as
shorten the drying time. It is important that the primer adhesive is completely dry prior to
applying the decorative material. Please follow all manufacturer instructions when using
a primer adhesive.
4. The panel should be placed in the support fixture.

Data and information provided free of charge by Schneller, LLC for corporate and/or educational informational purposes only. The information provided is believed to be accurate, but
Schneller and its suppliers do not warrant or guarantee such accuracy. Schneller expressly assumes no responsibility for the accuracy or usefulness of information provided by any third
party data or content provider. Schneller shall have no obligation to update or otherwise supplement or correct any data provided. Neither Schneller nor any of its data or content
providers shall be liable for any errors or delays in the content, or for any actions taken in reliance thereon.
 Heat Vacuum Application
AerFilm LHR® with Heat Activated Adhesive
Application Guide
August 2010 • Page 2 of 4

Procedure (cont.)
5. The decorative laminate is positioned over the panel, indexed and fastened to the
support tool. The material should not be in contact with the panel so as to minimize the
chance of wrinkling the material before it is hot enough to stretch. On some panels, it is
possible to pre-tack the decorative to the perimeter of the panel.
6. The silicone rubber sheet is brought into position and locked, sealing it around the
perimeter of the vacuum plate. An alternate method involves using the decorative
laminate as the diaphragm, replacing the need for a silicone blanket. Typically, this
method will allow for the material to be formed into recessed areas more easily versus
the use of a silicone blanket. Using this method, the support mold contains a frame that
holds the material along all edges and slightly above the panel surface.
7. The radiant heat source is started and positioned to pass heat through the silicone
rubber blanket or decorative material.
8. The vacuum pump is started and adjusted to 1-inch of mercury drawing the rubber sheet
along with the laminate into contact with the panel to minimize the slack in the blanket
during the heating process. If a wrinkle appears, the vacuum should be removed.
9. Although many temperature measuring devices and methods are available, it is
important to conduct experiments to ensure the actual glue line temperature is being
measured throughout the application process. As the temperature reaches 210°F
(100°C), gradually apply vacuum until a maximum of 25-inches (0.8 bars) of mercury is
reached. A typical cycle is as follows:
*Depending on the contour and type of panel (composite or aluminum), the minimum amount of
vacuum that will ensure contact of the decorative to the substrate and will yield an acceptable
adhesion level without allowing the honeycomb core to telegraph should be used. Typically, only 8-
10” Hg of vacuum pressure can be used on composite honeycomb panels.
TEMPERATURE VACUUM
Ambient to 160°F (70°C) 0 - 1 inches Hg (0 - 0.003 bar)
________________________________________________________________________________________________________
160°F to 210°F Monitor vacuum pressure
(70°C – 100°C) & temperature
________________________________________________________________________________________________________
210°F (dwell 4 minutes) Composite Panels: 8 – 10” Hg (0.24 – 0.3 bar)
(100°C 4 minutes) Aluminum Panels: 25” Hg (0.8 bar)
________________________________________________________________________________________________________
212°F to 100°F Monitor vacuum pressure
(100°C to 40°C)
________________________________________________________________________________________________________
< 100°F (< 40°C) Remove vacuum

Data and information provided free of charge by Schneller, LLC for corporate and/or educational informational purposes only. The information provided is believed to be accurate, but
Schneller and its suppliers do not warrant or guarantee such accuracy. Schneller expressly assumes no responsibility for the accuracy or usefulness of information provided by any third
party data or content provider. Schneller shall have no obligation to update or otherwise supplement or correct any data provided. Neither Schneller nor any of its data or content
providers shall be liable for any errors or delays in the content, or for any actions taken in reliance thereon.
 Heat Vacuum Application
AerFilm LHR® with Heat Activated Adhesive
Application Guide
August 2010 • Page 3 of 4

Procedure (cont.)
10. Dwell Temperature is maintained between 190°F (88°C) and 230°F (110°C) for four
minutes. (Ideally, the lower the temperature the better the texture retention and lower
gloss level. To fully activate the adhesive, a minimum temperature of 210°F [100°C]
should be achieved.)
11. The heat source is turned off, and the panel is allowed to cool down to <100°F (38°C).
12. The vacuum is turned off, and the silicone rubber frame is unlocked to remove the
panel with the decorative laminate.
13. The laminate is wrapped around the edges of the panel and window openings and
adhered with a heat gun. It is recommended to use a primer adhesive in all areas
where the decorative material will be wrapped around the panel.

NOTE: Other sources of heat including a convection oven, quartz bulbs and cal rod heating elements
have been successfully used in the application of AerFilm LHR®. A key feature on alternative
equipment is temperature monitoring equipment.

Troubleshooting
1. Panels with recess areas require vent holes to be drilled. Make sure all vent holes are
open to ensure maximum vacuum pressure. A No. 72 (0.0250” or 0.635mm) drill bit
provides a hole which is large enough to evacuate air, but small enough not to telegraph
through the decorative.
2. To ensure that the vacuum is uniform throughout the panel, the use of an open-cell foam
or bleeder cloth between the support fixture and the part can be utilized.
3. To ensure a correct vacuum pressure reading, the vacuum gauge should be relatively
close to the part. By having a vacuum gauge on the other side of the room, a false
reading may be obtained.
4. To prevent the decorative from delaminating in deep-draw areas, the use of a primer
applied on the part can provide additional strength. Care should be taken to ensure the
primer is dried completely prior to application of the decorative. If the primer is not
allowed to dry sufficiently, solvent blisters may result.
5. To ensure accurate temperature readings, the thermocouple should be attached to the
back of the adhesive. The substrate should be of the same composition as the part to
be covered.

Data and information provided free of charge by Schneller, LLC for corporate and/or educational informational purposes only. The information provided is believed to be accurate, but
Schneller and its suppliers do not warrant or guarantee such accuracy. Schneller expressly assumes no responsibility for the accuracy or usefulness of information provided by any third
party data or content provider. Schneller shall have no obligation to update or otherwise supplement or correct any data provided. Neither Schneller nor any of its data or content
providers shall be liable for any errors or delays in the content, or for any actions taken in reliance thereon.
 Heat Vacuum Application
AerFilm LHR® with Heat Activated Adhesive
Application Guide
August 2010 • Page 4 of 4

Troubleshooting (cont.)
6. To determine whether the material is forming in recess areas, tap the covered part with a
pen or a coin. A hollow sound indicates the decorative has not been bonded to the
substrate. Possible solutions:
1) Check to make sure vent holes are open.
2) Can a two-step operation be used?
a. Form material into flat areas
b. Insulate (shield) flat areas and continue heating and form into deep areas.
3) Determine whether the blanket may be the restrictive element. If the blanket is the
restrictive element, can the material be used as the blanket? Can a better forming
material, such as a silicone blanket or polyvinyl alcohol, be used as the blanket?

Data and information provided free of charge by Schneller, LLC for corporate and/or educational informational purposes only. The information provided is believed to be accurate, but
Schneller and its suppliers do not warrant or guarantee such accuracy. Schneller expressly assumes no responsibility for the accuracy or usefulness of information provided by any third
party data or content provider. Schneller shall have no obligation to update or otherwise supplement or correct any data provided. Neither Schneller nor any of its data or content
providers shall be liable for any errors or delays in the content, or for any actions taken in reliance thereon.