Friday, December 22, 2017

Fine-Patterned Replica Sleeved for Repeated Film Transfer Dec. 22, 2017

Recently, fine pattern processing and micron size pattern processing have been applied to the surface of plastic films.   These patterns result in unique functions in films.  Plastic films with these new useful functions are found in many fields.
These films are made by patterned master rolls.  Master rolls are pressed on films and uniques patterns are made on film surface.
Paterns on master rolls are made mechanichally.  They are so fine that this processing is quite expensive.

When this roll is used in mass production, abrasion is found on the master roll surface due to repeated use.  Then the master roll has to be made again.   It leads to the soaring roll cost.  
For this reason, there is for Film Transferin the film market on the cost effective master proessing.

▲Fine seamless pattern belt
We, Dymco, found out this cost-effective manufacturing process.

The outline of the process is like this:

1. The Master Roll
The pattern of the master roll is confidential matter for almost all users and quite expensive, in most cases the original master roll is supplied to Dymco from customers.  However, if we are asked, we can make patterns, too.

2.  The Mother Sleeve
Nickel plating (electroforming) is performed on the surface of the master roll.  This outer plated area is 'mother sleeve'.   Thickness of this mother sleeve is 0.1 to 0.3mm.

3.  Separation of the 'Mother Sleeve' from the Master Roll
The electroformed mother sleeve fits perfectly the master roll and those two are completely united. They are separated by Dymco' original separator unit.

4.  The Master Roll
The master roll remains.  It is stored with care until we make mother sleeve again. 

5.  Creation of Replica Sleeve
The separated mother sleeve, its inside is covered patterns made by electroforming.
Then we do electroforming once again in the inner surface with our original unit.
The outer surface is the mother sleeve and its inside is another sleeve, we call 'replica sleeve.'

6.  Separation of the Replics Sleeve from the  Mother Sleeve 
They fit each other.  They are separated by our another original separator.

Surface of this replica sleeve is just like the mother roll surface patterns.
Similarity of the two patterns is "sub μ " level.

7.  Application of Replica Sleeves to Mass Production Facility
The replica sleeve is attached to the main roll in the production facility.  
Then there appears patterns on the main roll.

This attachment on the main roll is possible if we add a little process on the main roll.    

8.  A certain number of replica sleeves are produced and stored.  One replica sleeve comes to the end of life, this replica is replaced by another replica.  This way the master roll is saved from abrasion.

The process to make replica sleeves is quite long and complicated . 
We do have lots of discussions with customers. 

DYMCO Major Products: Steel Belts   Metal Belts   Stainless Steel Belts   Steel Belt Conveyor  
Stainless Steel Belt Conveyor   Food Conveyor   Metal Sleeve  Positioning Conveyor  High tensile Stainless Steel Belts    

Major Applications:  Suction Transport   Transport in Clean Rooms   Electronic Parts Transport   Food Transport   Power Transmission