How to ensure the quality stability of different batches of full resin carbon ribbon?

The quality stability guarantee of different batches of all resin carbon strips is a systematic project that requires full chain control from raw materials, production processes, equipment, environment to finished product inspection. The following are specific safeguard measures:

1. Raw material control

Supplier certification: Select high-quality suppliers and establish long-term cooperation, requiring them to pass ISO9001 and other quality system certifications.

Incoming inspection:

Component analysis: Each batch of resin, wax, additives and other raw materials needs to be tested for component ratios to ensure consistency with the standard formula.

Physical properties: Testing key indicators such as melting point and viscosity, such as resin melting point tolerance, which needs to be controlled within ± 1 ℃.

2. Production processes standardization

Coating process:

Parameter locking: Key parameters such as coating speed (60-150m/min) and drying temperature (60-100 ℃) need to be locked through process documents and cannot be adjusted without verification.

Real time monitoring: The online thickness detector (accuracy ± 0.5 μ m) provides real-time feedback data and automatically alarms when the coating amount is abnormal.

Cutting control:

Tension system: The magnetic powder clutch controls the winding tension (accuracy ± 0.1N) to avoid stretching deformation.

Correction mechanism: The laser sensor detects edge deviation and automatically adjusts the position of the guide roller to ensure cutting accuracy.

3. Equipment calibration and maintenance

Regular calibration:

Coating machine: Calibrate the number of ceramic mesh roller lines every month to ensure uniform coating volume.

Cutting machine: Check the wear of the blades weekly and replace the passivated blades in a timely manner.

Preventive maintenance:

Lubrication plan: Regularly lubricate the transmission components according to the equipment manual to reduce friction losses.

Spare parts management: Key vulnerable parts (such as drive belts and bearings) need to have safety stock to avoid downtime and waiting.

4. Production environment control

Cleanroom:

Temperature and humidity: The constant temperature and humidity system controls a temperature of 22 ± 2 ℃ and a humidity of 50 ± 5% to avoid moisture absorption and deformation of the base film.

Dust management: The FFU filtration unit exchanges air 15 times per hour to ensure air cleanliness meets ISO Class 7.

Electrostatic protection:

Grounding system: The equipment and workbench are both grounded, and the static voltage is controlled within ± 50V.

Ionic fan: Ionic fans are equipped in the coating and cutting areas to neutralize static charges.

5. Finished product inspection and traceability

Full inspection items:

Thickness: detected by a beta ray thickness gauge with a tolerance of ≤ 3 μ m.

Printing performance: Sample printing test to verify clarity and wear resistance (no detachment after 50 wiping with alcohol).

Batch traceability:

QR code identification: Each roll of carbon tape is labeled with a unique QR code, which records information such as production batch, equipment number, and operator.

Sample retention system: 3 rolls of samples are retained for each batch, with a retention period of 6 months, to facilitate the traceability of quality issues.

6. Continuous improvement mechanism

Quality analysis meeting: Hold monthly quality analysis meetings to calculate the batch qualification rate (target ≥ 99.5%) and analyze the causes of defects.

PDCA cycle:

Problem identification: If the wear resistance of a certain batch decreases and the viscosity of resin B batch is found to be abnormal through tracing.

Countermeasure implementation: Revise the "Raw Material Inspection Regulations" and increase the frequency of resin viscosity testing.

Effect verification: Track 3 batches of production data to confirm the recovery of wear resistance.

Through the above measures, the quality stability of different batches of all resin carbon ribbons can be achieved, ensuring consistent printing effects and reliable weather resistance.