As a composite material integrating optical control, heat insulation and energy saving, safety protection, and aesthetic decoration, the final performance and appearance quality of architectural membranes largely depend on the maturity and stability of the molding process. The molding process is not only about combining the substrate with functional layers, adhesive layers, and protective layers in the designed sequence, but also a series of precision manufacturing steps involving surface treatment, coating deposition, composite pressing, and post-processing. This aims to ensure strong interlayer bonding, uniform thickness, stable optical performance, and good weather resistance.
The first step in the molding process is the pretreatment of the substrate. Regardless of whether polyester (PET), polyvinyl chloride (PVC), or fluorocarbon resin film is used, the surface must be modified using methods such as corona discharge, plasma, or chemical activation to increase surface energy and enhance the adhesion of subsequent coatings and adhesive layers. Process parameters in this step, such as power, gas atmosphere, and processing time, must be precisely controlled to avoid substrate aging due to over-treatment or interlayer delamination due to under-treatment.
Then comes the functional coating deposition stage. Depending on the product's functional positioning, methods such as vacuum magnetron sputtering, electron beam evaporation, sol-gel coating, or precision coating can be used to form metal, metal oxide, or functional polymer coatings on the substrate surface. For example, low-emissivity heat insulation films require multiple alternating sputtering layers of metallic silver or copper with dielectric layers within a vacuum chamber to achieve the desired balance between infrared reflectivity and visible light transmittance; the coating of dimming films may involve uniformly dispersed nano-conductive or liquid crystal materials, and the thickness must be controlled within the micrometer range to ensure the sensitivity of the optical response. The coating process requires real-time monitoring of vacuum level, deposition rate, and film thickness uniformity to prevent pinholes, color differences, and optical interference defects.
After the functional layer is prepared, the adhesive layer is coated and laminated. The adhesive layer typically uses solvent-based or hot-melt pressure-sensitive adhesives, uniformly applied to the functional layer or separate release film using methods such as microgravure, comma-shaped doctor blades, or slot coating. The lamination process is typically completed in temperature-controlled hot press rollers or vacuum laminators. By precisely setting temperature, pressure, and time, the adhesive layer is fully wetted, diffused, and a stable interface bond is formed between the adhesive layer and adjacent layers. For safety films or high-strength films, a polyester mesh or glass fiber reinforcement layer is often embedded during the lamination process to enhance tear and impact resistance. The lamination process must prevent the inclusion of bubbles, wrinkles, and impurities to ensure the flatness and optical consistency of the film material.
The final stage of the molding process involves surface protection and post-treatment. To improve the surface hardness, abrasion resistance, and stain resistance of the film, a UV-curable resin or nano-ceramic coating is often applied to the film surface, followed by rapid cross-linking under ultraviolet light. Some products also undergo UV-resistant edge sealing to extend their service life. Before roll forming, online or offline testing is required, including thickness measurement, transmittance and haze analysis, adhesion testing, and initial weathering assessment to ensure the finished product meets design specifications.
Overall, the architectural membrane forming process mainly revolves around substrate pretreatment, precision deposition of functional layers, adhesive layer lamination, and controlled post-treatment. Each step is interconnected and relies on high-precision equipment and strict process parameter management. Only in this way can architectural membranes with excellent performance and stable quality be continuously produced in large-scale production, providing reliable material support for the functional upgrade of modern building envelopes.