High Speed Roll To Roll Coating Machine For Polymer Plastic Films Heavy Film Metallizer

Royal Technology is a worldwide supplier of Roll-to-Roll web vacuum metallizing systems, which are applied in packaging, electronics, optical and flexible material industries.

Our research & development (R&D) are supported by professional engineers based in the United States (Darly Custom Technology) and the manufacturing facilities are located in Shanghai. With over 20 years experience, our high performance vacuum web metallizers can provide the types of coatings necessary for a variety of materials, like plastic films, paper, and non-woven materials etc.

Product Description:

R2R (Roll-to-Roll) web aluminum vacuum metallizers are machines commonly used in the manufacturing industry for depositing a thin layer of aluminum onto flexible substrates in a continuous roll-to-roll process. The process is widely employed in various industries; such as packaging, electronics, automotive and decorative applications.

Typically, the R2R web aluminum vacuum metallizer consists of different components, the first being an Unwind Station which is the process beginning with a roll of the substrate material which is unwound and fed into the machine.

After the substrate passes through a Cleaning Section in order to remove any contaminants, particles or impurities which may affect the quality of the metallized coating, it ultimately undergoes a Pre-Treatment Section which could involve corona, flame or primer treatment. This helps to enhance adhesion of the aluminum layer onto the substrate.

The Metallization Chamber is the central component of the machine, usually a vacuum environment where the aluminum deposition occurs. This chamber holds a number of evaporation sources and cathodes which heat the aluminum material to its evaporation point whereby the aluminum condenses onto the substrate and forms a thin, uniform layer.

Once the metallization process is complete, the coated substrate then passes through the Cooling Section to solidify and stabilize the applied aluminum layer.

Finally, the metallized substrate is wound onto a roll at the Winding Station, enabling further processing or use in various applications. R2R web aluminum vacuum metallizers provide several advantages such as, high production speeds, excellent control over the thickness and uniformity of the aluminum layer, and the ability to process a wide range of flexible substrates. Ultimately, these machines are important for creating functional and decorative coatings on materials such as plastic films, paper, foils and textiles.

The features of each R2R web aluminum vacuum metallizer may differ depending on the manufacturer and its intended purpose. Nevertheless, these machines are essential for producing high quality metallized coatings in the manufacturing industry.

Features:

The RT-R2R web aluminum vacuum metallizer features a range of practical benefits.

The high throughput reduces production cost while the high vacuum allows for heavy deposition layers – ideal for high barrier applications.

Its free-span process eliminates the drum line and edge trim while it is friendly for low tension substrates like CPP, BOPP and LDPE.

It features individual wire feeds and easy maintenance, as well as a precision web handling mechanism with Servo motor drives for accurate control at any line speed.

The RT-R2R is also designed with a compact design for easy installation using minimal floor space.

Double Evaporation Sources For Heavy Deposition

Technical Parameters:

The process of R2R (Roll-to-Roll) web vacuum metallizing involves depositing a thin layer of metal, typically aluminum, onto a flexible substrate in a continuous roll-to-roll manner. Here are the key steps involved in the process:

Substrate Unwinding: The process begins with a roll of the flexible substrate material, which is unwound and fed into the metallizing machine.

Cleaning and Pre-Treatment: The substrate may pass through a cleaning section to remove any surface contaminants that could affect the adhesion of the metal coating. Following cleaning, the substrate may undergo pre-treatment processes such as corona treatment or primer application to enhance the bonding between the substrate and the metal layer.

Metallization Chamber: The heart of the R2R web vacuum metallizing equipment is the metallization chamber. The substrate enters the chamber, which is maintained at a high vacuum. The chamber typically consists of a series of evaporation sources or cathodes, which contain the metal (such as aluminum) to be deposited.

Metal Evaporation: The metal within the evaporation sources is heated to its evaporation point. As the metal evaporates, it forms a vapor cloud within the chamber. The vaporized metal atoms travel in straight lines and condense onto the moving substrate, forming a thin, uniform metal layer.

Substrate Cooling: After the metallization process, the coated substrate passes through a cooling section, where the metal layer solidifies and stabilizes.

Substrate Winding: Finally, the metallized substrate is wound onto a roll, ready for further processing or use in various applications.

It's worth noting that the specific details and parameters of the R2R web vacuum metallizing process can vary depending on factors such as the desired metal coating, substrate material, and intended application. The process can be optimized to control factors like coating thickness, adhesion, and uniformity to meet specific requirements.

R2R web vacuum metallizing offers advantages such as high production speeds, precise control over coating thickness, excellent adhesion, and the ability to process a wide range of flexible substrates, making it a versatile and widely used technique in industries such as packaging, electronics, automotive, and more.

Applications:

WEB COATERS FOR PACKAGING INDUSTRY

Aluminum decorative coated plastic film and paper are essential in packaging applications. Royal Technology has developed some of the latest technologies that have higher productivity and lower operational costs. The new coating process avoids the heavy aluminum foil laminating, moreover, the heavy barrier (up to ONE micron thickness) metallized web is stronger and more resistant to moisture and oxidization.

Support and Services:

We offer complete technical support and service for Roll To Roll Coating Machine. Our experienced and dedicated technical staff are available to answer your questions and resolve any issues you may have.

We provide a comprehensive range of services, including troubleshooting, maintenance and repair, training, and software upgrades. We also offer remote support, so you can get the help you need even if you’re not near our office.

Our team is committed to providing the best possible customer service and technical support. We strive to answer all inquiries in a timely manner and work to find the most effective solutions for our customers.