PALIGHT Foam PVC Panels Fabrication Guide Overview of the PALIGHT Product Line Palram is one of the worlds largest producers of Free-Foam PVC Sheet products. The table below is provided to help you understand which Palight products are available and how they differ so you can be sure youre choosing the right product for your application. Application Product Print Graphics and Display Marine Construction PALIGHT Premium PALIGHT EPS PALIGHT Outdoor PALIGHT Marine PALIGHT Trimboard Colors Brightest White Array of Colors White White White White Sand and Clay Protective Film Palight 1-Sided Palight DF 2-Sided Palight NF No Film Not Available Not Available Not Available 1-Sided Weight Density and Rigidity Very Good Good Very Good Very Good Very Good Available Dimensions Widest Variety Limited Variety Limited Variety UV Protection Acceptable applies to white only Limited Ideal Limited Ideal High quality signs graphics displays and exhibits. Provides the best allaround performance for digital screen print applications and display fabrication. An Economical Print Substrate EPS. Great for lamination applications and cost-sensitive or short-term use digital and screen print applications. Signs and displays destined for long-term outdoor exposure. Available in smooth or wood grain finish. Available in dimensions that are suitable for outdoor use. Intended for marine or motor home applications. Seat backers cabinet partitions etc. Used in home construction as a wood replacement for interior or exterior trim moulding. Sold in typical trim boardlumber dimensions as well as full-size sheets . Feature Intended Use Each white color is specifically formulated per market segment. As depicted here PALIGHT Premium Foam PVC is available in a broad range of thicknesses. A wide variety of colors are also available. Other variants of PALIGHT are available for specific applications including PALIGHT EPS Outdoor and Trimboard. Some Foam PVC products manufactured by others may contain lead
. Palight is manufactured without lead or any other heavy metal. While Palram has manufacturing facilities in Israel China U.K. and the USA the majority of products sold by Palram Americas are manufactured in Kutztown PA USA. Contents Introduction to Palight 1 Hanging Signs 3 Features and Benefits 1 Adhesive Bonding of Palight 4 Cutting 1 Heat Bending 5 Drilling 1 Thermoforming 5 Milling 2 Heating Cycle 5 Routing 2 Processing Temperatures 6 Thermal Expansion Contraction 2 Painting 7 Screwing and Nailing 2 Graphic Applications 8 Installation 2 Direct Digital Printing 9 Exterior Signs 3 Laminating 9 Tips on Sign Installations with Posts 3 Chemical Resistance 12 Significant Items to be Considered 3 PSDS Information Replaces MSDS 16 Screwed Joints 3 Recommended Uses and Restrictions 16 Riveted Joints 3 Further Information 16 Frame Fastening of Flat Palight Sheets 3 Physical Properties Table 16 Introduction to Palight PALIGHT foamed PVC sheet is versatile flexible lightweight and durable and is ideal for use digital or screen printing fabrication and construction. PALIGHT Premium Foam PVC exhibits the whitest color available and has been successfully tested and approved by digital flatbed printer manufacturers worldwide. Printers and display builders will benefit from its consistent smooth and bright surface for producing high quality displays. PALIGHT is easily handled cut and fabricated using conventional tools and equipment and can be printed painted or laminated. Features and Benefits Ease of Fabrication Light Weight Chemical Resistant Superior Insulating Characteristics Moisture Resistant Great Flammability Ratings Heavy Metal Free Manufactured in the USA Israel and U.K. Cutting Circular Saws PALIGHT material up to 3 mm thick can be cut with a knife or blade. For Palight sheets 3 mm and thicker carbide-tipped triple chip ground type circular saws can be used. The following settings are recommended Rake angle 0 to 15 Clearance angle 10 to 20 Cutting speed 4000 to
8000 feet per minute Feed 70 to 90 feet per minute Tooth pitch 0.080 to 0.040 Band Saws High speed steel blades normally recommended for wood or plastic can be used for Palight material utilizing the following guidelines. 6 to 8 teeth per inch Cutting speed 3000 to 5000 feet per minute Feed up to 40 feet per minute Saber Saws Rough cut type blades ground for plastics can be used on Palight sheets. Smooth metal-cutting blades are not recommended. Drilling Palight can be drilled with carbide-tipped bits using twist drills recommended for metals. The following settings are recommended Point angle between 90 to 110 Spiral angle 30 Relief angle 10 Cutting speed 150 to 1300 feet per minute Feed rate 0.01 to 0.02 inches per revolution The minimum distance from the edge should be 2 times the hole diameter In an effort to reduce heat build up during drilling of thicker Palight sheets it may be necessary to periodically remove the drill bit from the Palight material. 1 Milling Palight can be milled by using standard milling machines of various types utilizing the following guidelines Relief angle 5 to 10 Rake angle -10 to 0 Cutting speed 3000 to 3500 feet per minute Cutting feed 0.12 inches per revolution Routing Palight material can be easily routed using multi-fluted carbide tools on standard woodworking routers. Standard tools and machines can be utilized with no need to alter equipment. Adjust feed and speed rates as needed to achieve the best edge finish on the Palight parts. Thermal Expansion Contraction As with most plastics Palight foamed PVC will expand and contract with an increase or reduction in temperature. This material property is known as linear thermal expansion and contraction. Since Palight can be used in a wide variety of indoor and outdoor applications linear thermal expansion and contraction may need to be considered during the fabrication and installation of the material. It is important to take in to account the temperature at which the Palight mater
ial was fabricated as well as the temperature of the installation. Palight should not be used in applications or climatic conditions that exceed 140 F ambient or surface temperature at which temperature the Palight will soften and permanently deform. Dark colors are generally not recommended for outdoor use as they absorb heat and can easily exceed the maximum allowable temperature of 140 F. Palight Linear Expansion Contraction Quick Reference Total Temp. Change Expansion Contraction of Material at Standard Lengths Widths in inches Distances Between Fastening Points for Screw and Rivet Joints Sheet Thickness Distance Between Fastening Points 2 mm 6 - 8 in. 3 mm 12 -16 in. 4 mm 20 -28 in. 48 in. 60 in. 96 in. 120 in. 20F 0.036 0.044 0.071 0.089 40F 0.071 0.089 0.142 0.178 60F 0.107 0.133 0.213 0.266 80F 0.142 0.178 0.284 0.355 100F 0.178 0.222 0.355 0.444 5 mm 31 - 43 in. 120F 0.213 0.266 0.426 0.533 6 mm 47 - 70 in. 140F 0.249 0.311 0.497 0.622 Screwing and Nailing Any type of screw or nail can be used to fasten Palight material. Power nailers and screw driving equipment are suggested. Inserting the screw or nail in an elongated slot or an oversized hole is recommended so that the material can expand or contract if fluctuations in temperature occur. For best results use oversized washers or grommets in combination with screws. Installation Palight is manufactured as an extruded foam PVC product with a directional grain running the entire length of the sheet. This manufacturing process gives Palight greater flexural strength in the direction of the extrusion. The grain of the Palight should always be installed perpendicular to the fastening point. 2 Exterior Signs Palight when used correctly and with basic mechanical fixing methods is suitable for exterior use. Using Palight can provide an excellent weatherproof sign substrate ready for screen printing painting or vinyl graphics. Tips on Sign Installations with Posts The following tips have been compiled to be u
sed as a general guide for fixing Palight for a minimum amount of breakage. Unusual designs falling outside the examples given may require certain modifications when considering Palight. Significant Items to be Considered 1. Bolt holes should always be larger than the bolt shaft to allow for thermal expansion and contraction thus eliminating the possible stress at bolt fixing points. The use of washers spread the compressive load when boltsnuts are tightened. Be sure not to over tighten as this will weaken the connection. 3
