The high reflectance coatings are applied to flat sheet product which is then deformed using specially adapted pressing techniques.

The coating technology employed allows the reflector shape to be made with minimum loss of reflective properties and well maintained coating adhesion and protection.

The special coatings used have excellent resistance to humidity and delamination even after forming.
Vegaform has been developed by Almeco within the Integrated Reflector Program (lRP).

Reflectivity

Vegaform material before pressing has a total reflectance of over 95%. Since the surface becomes extended during the forming operation and the coating is a hard ceramic layer, there is some change to the layers during pressing that results in a slightly reduced reflectance, depending on the depth and shape of the die. In a complex 3D shape this will obviously vary from one point in the reflector to another.

We have studied this process in depth using trial reflectors with controlled deformation to explore and define the limits of the process. After a deformation of 7,5%, Vegaform surfaces show a total reflectance of over 90%, much higher than the maximum reflectance value of post-anodized material. Values of 93% have been recorded on less heavily deformed surfaces , superior to our top SuperBrite finish (post-anodized reflectors made of a 99.98 clad alloy) by 6-7%.

In a formed reflector made from non-specular material, a small difference in surface reflectance is magnified many times due to the multiple reflections that occur within the unit. Consequently, even a small improvement in surface reflection given by Vegaform gives a much greater improvement in total light output compared to normal anodized reflectors.

Environmental tests

Temperature resistance

Panels of Vegaform V95100 have been held at a temperature of 250°C for 7 days and no reduction in reflectance values or change in visual appearance was observed. In the case of hard rolled products there is, of course, a softening of the aluminium but as Vegaform is already produced in a softened condition it is not so affected.

Humidity tests

In pure humidity tests, at 100% humidity at 38°C (ISO 6270-1) without the presence of salt, the Vegaform products show the same good resistance to deterioration as anodized aluminium. This has been confirmed by highly accelerated humidity tests with a condensing atmosphere wetting a panel at 90°C.

Salt spray test

The weather resistance of Vegaform has been proved by standard accelerated tests in Almeco's laboratories in Milan.
In Salt Spray testing (UNI EN ISO 9227 - ASTM 8117), vacuum coated enhanced materials generally do not quite meet the high resistance standards achieved by pre or post anodized aluminium.
The resistance of Vegaform is similar to that of normal Vega 95 and a typical Vegaform reflector shows no significant deterioration in surface properties after exposure for 100 hrs in Neutral Salt Spray and little deterioration after 240 hrs. Vegaform is suggested for use in luminaires with a high IP rating.

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