porovision systems at fast running webs or fabrics

Optical nano micro porovision systems at fast running webs or fabrics

Online porosity permeability control

Sophisticated Laser applications – intelligent sensor scanner system

Sophisticated, multi functional, optical online sensor systems 

IPM has developed a number of new, patent pending, stationary, scanning optical control processes, devices and systems for fast moving webs or fabrics to detect very precise and reproduce their specified product properties in online operation during production.

Introduction

OPSS-1 OPRL-1 vision control systems are equipped with multiple IR, NIR, VIS monolithic spectral color sensors, precision line lasers, CCD imagine devices, DSP, ATMEL and INFINEON sensor internal controllers, own firmware, high speed data link, at scanning speeds from 20–500 mm per second, at web widths up to 5000 mm, measuring gaps from 2.0-5.0 mm, optical inline detection of permeability, porosity, spectral transmission, opacity, extinction, particle absorption, porosities ranges from 80 up to 5000 C.U. (Coresta), respective from 50 down to 3 Gurley, position control of micro perforation lines with 0.1 mm accuracy, nano micro pores from 50 nm up to 200 micron diameter by up to 300 pores per cm2. With real time data determining of certain parameters, optical transmission, spectral grades, porosity integrals, envelope curves, internal calculated measuring values.

Thus direct with close loops and feedbacks to the power electronics of fabrics treatment units. Micro perforation or other system makes it possible to compensate any changes in web treatment parameters and their partial locations so that each jumbo roll as well single, quad bobbin sets can be produced quantity and quality controlled without intermediate stops in order of ISO 9001/9002 certifications.

Thus sophisticate, precise, liable, repeat accuracy, easy visualized, optical online measurement techniques archives perfect ways to control and convert pneumatic, fluid, gas, jet streams, static permeability, naturally porous grades, filtration levels, breathable or ventilation effects, etc. at fast moving webs. Their conditions can be easily met by using optical transmission technology thanks to described processing in fully online stationary or scanning control units, extremely small pore dimensions, high fabric speeds up to 1000 m/min by high repetition rates. That completely independent from base material properties as consistency, coloring, density, formation, pin holes, smoothness, stretching, shrinking, brightness, opacity, optical spectral, Raman, property, gauging thickness weight, moisture content and other known influences.

Applications

The electrostatic nano or micro perforation, including Co2 slab fiber yag excimer diode laser, other material going trough or surface treatment, as well for micromachining and nanotechnology, is usually used depending on quality at fine, rotogravure or offset printing, holographic or publishing paper, writing, magazine, newspaper, flexo, packaging, bonded fabrics, non-woven, filter, coffee, tea, bag, sack, craft, food, fresh fruit, force, reinforce, tipping, cigarette, plug wrap, fiber, facial tissues, toilet, decoration, wallpaper, gift, watermark, towels, bleached dyes shiny or clay, recycling, booklet, bible or other special paper, certain plastic films, foils, coating, laminating, converting, extruding, Polyofine, Polysulfone, Elastomer, textile, Polymer or most of that varied types.

It is also used especially for additionally treating materials when aiming special characteristics by physical or regular process reasons cannot be achieved by other process technologies. Material base weights from 10 up 150 grams per m2 by thickness from 5 up to 100 micron are possible to use. Including defect inspection, process automation, moisture vapor transmission rate, abrasion resistance for lamination of waterproof and breathable fabrics.

Our state-of-the-art, industrially approved, sophisticated, compact, multi functional, optical online sensor scanning systems together or without electrostatic, laser perforation technology operates precise and reliable 24/7, are integrate able into existing rewinding, slitting, spooling, spreading, printing, labeling, complex production lines or other machines and other production processes as well. Also, they can be used as completely independent micro surface-all-over or zone perforation units. Fully new ranges of applications will be made available total new products with special features.

Specific information by below website links and patent resources.

Porosity control of nano or micro porous and/or perforated web material, with laser or electrostatic perforation systems, which are produced in speed ranges up to 600 m/min and web widths up to 2000 mm are difficult to control with pneumatic systems because that methods includes disadvantages such as web tangency, web toughing, material flaking, folds build-up, dust and dirt flowing in the system.

These difficulties are ideally solved with stationary/scanning optical porosity control systems as OPSS-1, OPSS-1-A/B, OPRL-1 A/B which are patent pending by DE10251610 and patent grant 200310104764 in China.

Air or gas permeability or porosity ranges from 50 up to 5,000 C.U. (ml/sqcm/min) respectively 3 to 100 l/sqm/sec. Frank system by web widths from 100 to 2000 mm at speeds of up to 500 m/min are now possible.

Working principle

The online quality control technique is performed to detect and scan zones, generated nano micro pore areas or lines in using multiple colour sensors and a precise tiny line laser which are linked to sensor internal controller units. It controls roll or bobbin formats as stand along or mechanical coupled devices on existent scanning units which measure material weight, thickness, formation, smoothness, roughness, opacity, etc. in web widths up to 6000 mm.

For lasers or electrostatic perforation in bobbins and wide paper webs online measuring procedure and their devices are indicated, with which same transverse movement and simultaneously collections of perforation positions, perforation profile quality and porosities with two different sensor systems and locations. Zone or line position detection by accuracy of 0.1 mm with a laser line unit, scanning speeds up to 300 mm/s, DSP controller firmware, high-speed serial link up to 230.400 bit/s, industry PC performance, C++ process/visualisation software for production quantity, quality, statistics, LAN to quality control centre, etc.

With transverse movements of both measuring systems across the web width, consisting of line laser to detect the quality and position of single nano, sub micro or macro holes in ranges of 10 nm up to 200 um, groups of holes or determined perforation zones and in the same time as the light transmission sensor unit monitors the porosity profiles and determined their integrals continuously. 

Thus direct feedbacks to the perforation or machine system enable the trend compensation of arising changes that production rolls without intermediate stops are high quality and quantity controllable.

Applications

Jumbo roll by roll production for offline micro laser or electro static perforation machines for web widths from 100 mm up to 2000 mm, porosity ranges from 80 C.U. up to 5,000 C.U. with feed backs to each perforation channel and automatic production control. The OPSS-1 system enables a production networking for laser or electrostatic perforation machines in quality and quantity aspects in order of ISO certifications.

As well for porous, filter, permeable paper, packaging, sack, fabrics or other webs at making, finishing, refining or other industry machines or processes.

IPM- International Perforation Management

high-tech engineering - China – Germany - Thailand

Mr. Werner Grosse

Tel./fax : 0049-3212-5097465

http://www.microperforation.com

http://www.microperforation.com.cn

http://www.deguodaguan.com/ipm/

http://www.dk3qv.de

Micro Perforation

Material webs such as cigarette, tipping, filter, coated, bag or packing paper, 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 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 µm 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., by webs from 100 to 2000 mm at web speeds of up to 500 m/min, depending on porosity and material consistency in relation to its ability to perforate.

Patent grand for process and device DE10328937 of IGBT power switching unit.

Laser perforation

Perforate by pulsed or enlarged focused laser beams holes sizes from 60 to 200 µm, typical hole densities from 10 to 30 holes per cm, holes sequences from 100.000 to 500.000 per second at a maximal 16 perforation heads distributed over the width are possible with traditional laser systems/machine. Their porosity levels are from 100 to 3000 C. U., normally with web widths up to 500 mm and web speeds of up to 600 m/min.

IPM – International Perforation Management - owns development of laser perforation technology LPM-1, patent grant by DE 102004001327, operates with quadruple beam inputs up to 8 KW into a high power CO2 laser beam multiplexer to generate up to 200 individual laser perforation rows across the web, combines automatic positioned laser perforation heads, focus setting, web speeds up to 400 m/min, web widths up to 2000 mm, up to 3,000.000 holes per second, jumbo roll by roll production, optical online permeability/perforation line positioning control, porosity feedback, high automation grad and other features. Each laser perforation lines are archive able from 100 up to 1000 C.U.

MLL-1 Micro Laser Line Perforation for holes pattern, perforation design, e.g. waves, zigzag lines, line packages, cryptograms, company logos, holograms, anti counterfeiting product indicators. Patent pending for process, device and product property DE102004012081.

New ranges of applications will be made accessible as new products with special features will be developed.

Dyne control

Described is a method and device for optical inline tough less surface tension control ODSTM-1 by which the fast moving substrate runs through the measuring gap. It’s transmitted with a chromatic beam and spectral selected light source were two optical channels are displaced and polarized by 90 degree to each other. Both optical axles are precise and motor driven shift able in certain angles from 25 up to 65 degree. The spectral light photons, transmission, extinction, absorption grades are detectable by two optical CCD imagine vision devices which are integrate in the sensor case on the other side of the substrate.

Material

Moving substrates means plastic foils, flexible, high-tech films, laminate, coating, bonding, labeling, co-extrusion, BOPP, LDPE, LLDPE, HDPE, MDPE, MAS, MEV, PET, FEP, PP, PE, PS, PO, EVA, PTFE, PVC, PTFE, DPC, BOPS, Vinyl, Polyester, Wrapping, Olefin, self-adhesive tape, high strength, cross-laminated, adhesive-coated films, reflective or magnetic sheeting, automotive tape products, inkjet media, Polyethylenex, heat sealing, sewing of plastic film, security, pressure sensitive tapes for the entertainment industry, graphic and specialty arts for general industrial and electrical applications, building or engineering industry, photographs, masking or printable plastic films, flat or corrugated rigid foamed thermoplastic sheets, polycarbonate, acrylic.

PETG, extruded or polished cellulose, optical grade polycarbonate, sheets for IR or laser protection, welding filter grade sheets, films for video, imaging, capacitor or thermo transfer applications, foamed polypropylene film with decorative ribbons, binary-oriented polystyrene sheets, multi layer co-extruded film, high impact PVC and PETG, polyimide film, tape and flat films for aerospace automotive medical agriculture marine automotive household commercial domestic construction industry, municipal and leisure applications, clear matt semi-matt finishes or colored, micro porous membranes for use in alkaline lithium batteries, fuel cells and filtration equipment. By gauges from 10µ to 100µ, fabric widths up to 10,000 mm and web speeds up to 18 meters per second.

Optical properties

Material specific wavelength selection between 1200-1800nm, material specific finger prints, molecular spectral properties, transmission grades, optical angle scanning, Lambert Beersche law determining, ultra low level stray scatter light detection, polarization, slot diaphragms, transverse displacements control the light beams along/far from the optical X and Y axes. The results are extreme scattering, diffraction, NIR, IR, stray light photons generation into the layer areas at both sides of the moving substrate. Their reflected and transmitted light intensities enables the determination by defined formulas and data matrixes the surface tension values in ranges from 28-62mN/m which are direct associate and bond to real static values for Statistical Quality Control (SQC).

And this entirely independent of the material specific influences as like surface consistency, thickness, density, weight, opacity, coherence, filling, stretching, shrinkage, structure, co-extrusion, polar grouping, temperature, intrinsic motivation or viscosity, hydrophobia, hydrophilic molecules, hydrogen, photonics, mol mass, moisture, water steam proof, bi-layer, polymer, patterning, nanostructure, irradiation, isotopic, catalyst, multi atomic, coherence, absorption, photo mask effect, roentgen, X-ray, radiation, resonance bands, REM, TEM, FIC, IEC, ESCA X-Ray, Raman, Lamber Beersche law, electron spectroscopy for chemical analysis ASTM or ATR method, property, ellipsometry, opto-acoustic photonic liquid effects, pre material treatment as corona, plasma, flam treatment.

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Patent grand for high power 200 optical channel laser multiplexer, high voltage, high frequency ultra short current pulse converters, unique laser product designs, marking, logos, scripts, security paper, cryptograms, cutting, welding, drilling, melding, ablation, hardening, process, gold, silver, stainless, steel, glass, brass, cupper, aluminum.

Mass product treatment, ventilation, breathable, penetration, air, oxygen, gas, jet stream, fluid, liquid, vapor, waterproof, product property, medical, biological, industry, tobacco, domestic, space, aircraft, defense, military. Anti counterfeiting, high security, quality level, high power, slab, Co2, excimer, yag, uv, fiber laser.

Since 1979, electronics, application, operation engineer, project manager, entrepreneur, director, technology expert, professional career, research assignments, 46 inventions, 34 patents. Organization, joint ventures.

Lectures, engineering reports in English, Spanish, German, French, Italian, Thai, Mandarin.

Cooperation, contacts in China, Indonesia, USA, France, Spain, Germany, Russia, Georgia, Saudi Arabia, Yemen, Sudan, Syria, Jordan, Nigeria, Cambodia, Vietnam, Pakistan, India, Iraq, Iran, Korea, Japan, Argentina, Chile, Cuba, Venezuela, Mexico, Brazil, Thailand, Ukraine, South Africa. Several honorary for excellent cooperation and technology transfer from Chinese and other governments.

Specific information by below website links and patent resources.

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