Nano, micro perforation or surface treatment of substrates and diverse running webs Material webs such as cigarette-, mouthpiece tipping paper, filter-, coated special papers, force papers, bag papers or packing papers, bonded fabrics, spun bonded non-woven, technical textiles, fabrics, laminate, etc. with base weights from 20 g/m2 to up to 150 g/m2, up to
20 g/m2 LPDE coating films, are perforated electro-statically - ESP - nano/micro or laser or mechanical micro or macro for different application purposes.For a better comprehension: Electrostatic - ESP - NANO/MICRO PERFORATION are statistically irregularly distributed, varying by size up to 40 %, and analogically, under LASER or micro/macro mechanical PERFORATION, evenly arranged in diameter about the same in size, at best non-inclined holes und rows of holes of diverse arrangement.
For the human eye invisible electrostatic - ESP - nano or micro perforations may be arranged in areas as well as in zones with specific distances within its web. The sizes of the holes range from 1 to 120 =B5m in diameter and hole sequences from 1.5 to 16 million pores per second. Arrangements of zones are usually carried out in width from 2 to 6 mm and pore density of 15 to 250 pores per cm2 whereas the perforation of areas results in pore densities of up to 2 million pores per m2. ESP perforations allow for porosity levels from 80 to
2500 C. U., width of webs from 100 to 2000 mm at web speeds of up to 500 m/min, depending on the porosity and material consistency in relation to its ability to perforate.Laser perforation Possible to perforate by pulsed or enlarged and focused laser beams are hole sizes from 60 to 200 =B5m at density of holes of typical 10 to
30 holes per cm, hole sequences from 100.000 to 500.000 holes per second at a max. of 32 punctured rows by laser distributed over the width of the web with traditional systems or machine. Their porosity levels range from 100 to 3000 C. U., normally with web widths from 100 to 500 mm at web speeds of up to 600 m/min, depending on the porosity and material consistency in relation to its ability to perforate.IPM owns development of LASER PERFORATION technology LPM-1 is patent grand and operates with quadruple beam inputs to a high power CO2 laser beam multiplexer to generate up to 200 individual laser perforation rows across the web, combines automatic laser perforation head positioning, focus setting, web speeds up to 400 m/min, web widths up to 2000 mm, up to 4,000.000 holes per second, jumbo-roll-by- roll production, optical online permeability and perforation line positioning control, porosity feedback and other features. Each laser perforation lines are archive able from 100 up to 2000 C.U.
The conception of high-power laser beam multiplexers enable many possibilities in other industry application fields as cutting, cut- offs, welding, surface finishing, drilling, polishing, forming, surface treatment, roughness improvement, etc. Each of the 200 single perforation head can be positioned across the running web or static positioned material. The automatic processes, equipments and devises opening completely new possibilities in industry, science, military or space laser application.
A new patent pending Micro Laser Line perforation technology MLL-1 generates sinus, waves, zigzags or other kinds of perforations cryptograms, designs as multiple pairs of micro laser lines in the web direction. Provide for tipping, cigarette, packaging or other kind of paper webs. These special features of micro laser line perforation enables fundamental new product characteristic in perforation scripts, e.g. for mouthpieces with tipping paper on cigarette filters, products indication with visible perforation holes as brand name or company logo, anti counterfeiting designs, perforation cryptogram, etc. As well is that process to use by other material, industry and application field.
Perforation of tipping and cigarette paper webs for ventilation of filter cigarettes The electrostatic ESP perforation has been used more then 25 years for ventilation of non filter or filter cigarettes to create a directed and guided air bypass. For this purpose, cigarette paper for some non filter cigarettes and almost every kind of filter cigarettes tipping papers are perforated electro-statically ESP OFFLINE and in zones from
2.0 - 6.0 mm width or rows ONLINE or OFFLINE by the use of lasers in order to reduce the harmful substances such as nicotine and condensate down to allowed values. Another effect is the possibility of guiding and controlling the degree of ventilation of the Cigarettes.Special applications and product properties with ESP electrostatic perforation One of the foremost postulation which can be applied to many application purposes and products containing bonded fabrics, bag- or packaging papers, non-woven, etc. with gas or steam permeability but water impermeability will be found at the application stage of the ELECTROSTATIC NANO/MICRO PERFORATION TECHNOLOGY. Which means pore sizes from 0.5 up to 10 =B5m diameter by up to 5 million per m2. This is due to the water's greater surface tension which hampers the permeation through the relatively small nano or micro pores. These and other physical advantages of the relatively small pores necessarily demand the application of the ESP perforation method because alternative perforation or processes are NOT feasible, too expensive or simply uneconomical and would not lead to a successful application.
To archive new ESP demands IPM developed/patent grant new electronic perforation circuits which working as upward converters with IGBT's, MOSFETS's or HVFET's for power pulses from 1 =B5s up to 25 =B5s, high current peaks up to 300 Amps, base frequencies up to 200 KHz on ferrite transformers to generate 50 KVss to each sparking electrode.
Optical online permeability or porosity control Since naturally porous web materials or web materials to be perforated are processed with speeds of up to 600 m/min and web widths of up to
2000 mm are used, a pneumatic porosity measuring, hence measuring whilst touching the web are highly difficult. Further difficulties of pneumatic measurements are the disadvantages of rising of web tension, material abrasion, folding, leakage at measuring head, impurities, non linear processing and calibration problems.Thus, optical measuring offers better ways for transmission measuring the pneumatic static permeability for naturally porous or nano, micro or macro perforated webs. The conditions mentioned above can be easily met by using the optical porosity measuring technology thanks to the mentioned product processing and online control, extremely small pore dimensions, relatively high track speeds and a good value repetition. That full independent from principle material facts as consistence, thickness, weight, coloring, formation, smoothness, brightness, opacity, and other influences.
Therefore, IPM - International Perforation Management - has developed a number of new, patent pending, stationary and transverse optical measurement processes and systems which working with multiple color sensors, a precision line laser, scanning speeds from 20 - 200 mm per second, porosity ranges from 80 up to 3000 C.U., perforation lines detection by 0.1 mm, nano/micro holes sizes from 0.5 up to 2000 =B5m diameter and up to 250 holes/cm2 to determine all data in real time with an internal controller unit in order of multiple light transmissions and perforation profiles to determine envelope curves as well porosity integrals.
Thus direct feedback into the perforation system makes it possible to compensate any changes in terms of porosity and perforation locations so that each jumbo production roll up to 25,000.00 meters as well single or quadruple bobbin sets can be produced/controlled without intermediate stops and certificated in quantity und quality on their end.
Future prospects The electrostatic ESP nano or micro perforation usually applies within ranges of the refinement of fine paper, packaging webs, bonded fabrics, non woven, filter paper, bag or force paper as well as special paper webs of most diverse kind especially when additionally treating course materials for achieving special characteristics which for physical or process reasons cannot be achieved by other process technologies.
Our highly modern, industrially approved ESP perforation technology operation which even can be relied on when operated 24/7 can be integrated into existing rewinding course devices or other course devices. Also, they can be used as completely independent perforation devices.
New ranges of applications will be made accessible as new products with special features will be developed.
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IPM - International Perforation Management High-tech engineering - China - Germany - Thailand
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