The wrinkles of films occur at transfer and processing

Now, most of the companies using the roll-to-roll process have wrinkle problems occur at transfer process of films.
Change of material and thickness might cause wrinkles or meandering.

Those problems are

①Equipment factors, such as non-levelness or non-parallel of the roll.
②Base material factors, such as unevenness of thickness,
characteristics of material, environmental temperature and storage condition.
③Inflow of air between the base material and roll at high-speed transfer.

Mostly those factors are combined to cause the problem.

For the countermeasure, some users plan of major customize of the machine or renewal.
For another countermeasure is to add expander roll in the existing machine or replace the existing idle roll to expander roll. We have many results of eliminating the wrinkles perfectly by this method.

Resolve example

Failure rate of the year became 0

Details of consultation：

We handle adhesive film at the rewinding process. If the wrinkle occurs, the adhesive on the film will stick together. We improved the storage condition to keep the base material in good condition, but the solution is not good enough.

Proposal：

Install expander roll at the wrinkle occurring position. Also, the temperature condition will change in each season. This temperature condition difference cause the different wrinkles each season. We propose using Variable bow expander roll. Now the failure rate of the year of this plant is 0.

The base film material has been perfectly laminated！

Details of consultation：

The film changes from ordinary, one side slack appeared and not able to laminate perfectly.

Proposal：

Proposed to install Variable bow expander roll just before lamination process. The film was stretched before the lamination process and able to laminate perfectly. The effect of the expander roll was more than the customer expected. The manufacturing loss at the lamination process was enormous and they were surprised to the result.

Manufacturing loss of the thin film reduced and also operators burden reduced too！

Details of consultation：

From the change of the film thickness to thinner film, wrinkles appear and base material break occur. It needs enormous time for restoration and we suffer enormous manufacturing loss.

Proposal：

As we confirmed the site, the operator was continuously monitoring of the wrinkle appearance.
We proposed to install of Electrical variable bow expander roll to the wrinkle frequent appearance point. Wrinkle occurrence reduced and manufacturing loss reduced also. Later on, the wrinkle detection camera system was installed. Combination of Electrical variable bow expander roll and Wrinkle detection camera system become auto variable bow system. Now it is used to eliminate the wrinkles automatically and the burden of operator reduced.

Our proposal of installing Expander roll

Addition of expander roll is inexpensive compared to the major customize of the machine. Compared to the other spreader roll, Expander roll has the most spreading force. Use different base material in same machine, easy to adjust by using variable bow expander roll.  Install of Expander roll will improve the product quality, manufacturing loss and yield rate. Reduce the burden and maintain safety of operators by using Auto variable bow system or Wrinkle detection camera system.

Wrinkle occur

Wrinkle eliminated

Achievement of use in film material.

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