How to control the thickness uniformity of all resin carbon ribbon during the production process?

The thickness uniformity of all resin carbon ribbon directly affects printing clarity and durability, and its control needs to be integrated throughout the entire production process. The following is an analysis of key control technologies and equipment:

1. Base film treatment and corona activation

Base film selection: Select polyester (PET) base film with high thickness uniformity, and the thickness tolerance should be controlled within ± 0.5 μ m.

Corona treatment: The surface of the base film is uniformly activated by high-voltage electric motion sickness machine to improve adhesion. The treatment strength needs to be tested by a Dyn pen (usually ≥ 38 Dyn).

2. Precision coating process

Gravure coating machine:

Ceramic mesh roller: The number of lines (100-250 lines) determines the coating amount and requires regular calibration to control the ink layer thickness.

Coating parameters: speed (60-150m/min), pressure (0.1-0.3MPa) need to match the number of mesh roller lines.

Multi layer coating:

Back coating: thickness 1.2-2 μ m, containing anti-static agent.

Release layer: thickness 0.5-1 μ m, controlling the peeling force.

Ink layer: thickness of 15-17 μ m, determines the printing quality.

3. Drying and curing control

Hot air circulation oven:

Segmented drying: Back coating at 60 ℃, ink layer at 80 ℃, to avoid coating cracking caused by high temperature.

Wind speed uniformity: Ensure even distribution of hot air through baffle design, with a temperature difference of ≤ 5 ℃.

4. Cutting and winding technology

Carbon ribbon slitting machine:

Tension control: The magnetic powder clutch automatically adjusts the winding tension (accuracy ± 0.1N) to prevent stretching deformation.

Correction system: Laser sensor detects edge deviation and automatically adjusts the position of the guide roller.

5. Online monitoring and feedback

Real time thickness detection:

Beta ray thickness gauge: non-contact measurement with an accuracy of ± 0.5 μ m.

Closed loop control: data feedback to the coating machine, dynamically adjusting the coating amount.

6. Environmental control

Cleanroom:

Temperature and humidity: Temperature 22 ± 2 ℃, humidity 50 ± 5%, to avoid moisture absorption and deformation of the base film.

Dust removal system: HEPA filter filters particles larger than 0.3 μ m to prevent coating defects.

Quality control standards

Thickness tolerance: The overall thickness tolerance is ≤ 3 μ m, and the single-layer coating tolerance is ≤ 0.5 μ m.

Testing frequency: 5 rolls per batch, with 10 points tested per roll.

Through the integration of the above technologies, the uniformity of the thickness of the all resin carbon ribbon can be controlled within ± 1.5 μ m, ensuring stable printing quality.