Abstract
Flexible continuous plastic films are used to produce various products, including optical films and packaging materials, because plastic film is suited to use in mass production manufacturing processes. Generally, the web handling process is applied to convey the plastic film, which is ultimately rewound into a roll using a rewinder. In this case, wrinkles, slippage and other defects may occur if the rewinding conditions are inadequate. In this paper, the authors explain the development of a rewinder system that prevents wound roll defects—primarily starring and telescoping. The system is able to prevent such defects by optimizing the rewinding conditions of tension and nip-load. Based on the optimum design technique, the tension and nip-load are calculated using a 32-bit personal computer. Our experiments have also empirically shown that this rewinder system can prevent roll defects when applying optimized tension and nip-load. Additionally, inexperienced operators can control this system easily.
Highlights
Thin, flexible plastic films are widely used in various fields as different materials, including functional and packaging materials
Common examples include the optical films used in liquid-crystal displays (LCD) and packaging films used for the storage and transport of foods
Concept behind Rewinding Condition Optimization In actual manufacturing lines, the web width, thickness, and mechanical properties often differ depending on the item being produced
Summary
Flexible plastic films (webs) are widely used in various fields as different materials, including functional and packaging materials. Common examples include the optical films used in liquid-crystal displays (LCD) and packaging films used for the storage and transport of foods The reason for this is that webs are suited to use in mass production and can be given moisture proofing, light blocking, optical properties, and such in a continuous process. H. Hashimoto rewinding condition settings are inappropriate, defects such as slip, telescoping, and wrinkles will occur in the rewound roll. We believe that by theoretically determining the internal stress, we can predict and prevent such defects ahead of time In this light, Hashimoto et al have proposed a rewinding tension optimization method designed to prevent slip and wrinkles inside the roll [1]-[3]. We investigate the optimal rewinding conditions, including tension and nip-load, and developed a rewinding system in which the software is integrated to minimize rewinding defects
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