Phenomenon and Causes of Poor Coating Gap
1. Tail
(1) In terms of materials: slurry material, viscosity, solid content, slurry (surface) tension
(2) Equipment aspect: Coating back roller distance The speed and diameter of the coating roller when the back roller bounces open Material of the back roller surface. The back roller is deformed The parallelism between the back roller and the coating roller, and the non parallelism between the back roller and the front roller of the oven Tension during operation.
(3) In terms of operation: parameters for adjusting the head and tail
2. The head and tail are not parallel
(1) In terms of materials: the gravitational force on both sides of the substrate is uneven.
(2) In terms of equipment: the horizontal planes of the back roller and the coating roller are not parallel; When the back roller bounces open, it is uneven on both sides; The coaxiality of the back roller surface, the non parallelism between the back roller and the traction roller, and the horizontal changes.
(3) Tension adjustment roller adjustment status
3. The front and back are not aligned
(1) Operational aspect: Consistency of the first gap The running parameters have not been properly adjusted The naked eye is blocked The unwinding and feeding rollers forgot to clamp
(2) In terms of equipment: there is a high tension behind the second side Low tension in front
4. The blank space decreases during the middle startup, and the accuracy of the last 3-4 pieces is not accurate
In terms of equipment: The initial tension during startup is inaccurate, and there is no memory function on the first side. When starting up, the foil slides forward by 2-3mm. The tension is first turned on during startup, and the back roller does not rotate. The coating head has no clamping roller or is not clamped.
5. The latter one has a parallel tail
In terms of operation, the distance between the coating back rollers (with the first side trailing and the second side not trailing); The back roller pulls slowly when the machine is stopped
6. Thick head and thin tail or thin head and thick tail
Operational aspect: The head and tail parameters have not been properly adjusted.
7. Actions have no effect
(1) In terms of materials, the elasticity on both sides of the foil material is uneven
(2) In terms of equipment, the foil material leaves the back roller in an instant when the tension is low Distance between coating rollers
8. Double sided large blank space phenomenon
The optical eye does not sense, the first gap is abnormal, and the optical eye is blocked
two
The coating section length changes and the spacing is unstable
1. Significant changes in segment length (* shortening) * Small changes in spacing (narrowing)
Fault Cause
1) The surface of the back roller and rear rubber roller is not clean;
2) The gap between the back roller and the rubber roller is too small and too tight;
3) The front and rear tension is not matched, and unwinding is greater than rewinding.
Solution
1) Clean the roller
2) Adjust the inclined block to a fixed position
3) Adjust according to the set parameters
2. The segment length changes greatly (* becomes shorter) and the spacing changes greatly (becomes larger)
Fault Cause
If the length of the head of the pole piece and the head of the next piece changes greatly (decreases), and the tail between the two sections of the pole piece changes less, it can be judged that the solenoid valve (controlling the movement of the rubber roller) is not flexible.
3. Significant changes in segment length (* increase in length) * significant changes in spacing (increase in width)
Fault Cause
1) The surface of the back roller and back rubber roller is not clean,
2) Without a pinch roller, it may not be clamped or lost control
3) Mismatch of front and rear tension, winding is greater than unwinding
Solution
1) Clean the roller
2) Add pinch rollers
3) Adjust according to the set parameters
three
Reasons and countermeasures for the wrinkling phenomenon of the polarizer during the operation of the coating machine
1. The overall installation accuracy is low, and the installation center of each component deviates from the design center line of the whole machine or has an angle with the design center. The foil strip will be severely wrinkled, and the installation center must be adjusted.
2. Excessive parallelism between the rollers can cause wrinkling of the foil strip. It is necessary to carefully check whether the vertical projection plane is not parallel or the horizontal plane is not parallel, and then adjust it accordingly.
3. When the roughness of the roller surface exceeds the tolerance, the roller surface is not smooth enough, and there are obvious processing textures, it can also cause the foil to wrinkle. The manufacturer needs to be requested to replace it.
4. There are foreign objects sticking to the back roller and each passing roller or excessive use of water Isopropanol scrubbing requires regular inspection, timely detection and cleaning, and care should be taken not to damage the roller surface.
5. The foil joint is poor, and the tension on both sides of the foil is unbalanced, causing the pole piece to wrinkle. First, adjust the tension adjustment roller under the coating head. After the foil gradually stabilizes, adjust the adjustment roller to its original state.
When the gap between the back roller and the coating roller is not consistent when they are in close contact, the pole piece will wrinkle. Coating Online believes that regardless of whether the first or second side is coated, the gap should be carefully adjusted. First, the gap should be appropriately expanded, and then slowly reduced. At the same time, observe the dial scale at the moment when the coating roller just touches the foil strip, and then reduce the gap by 0.03mm.
7. When the correction system is abnormal, there may also be wrinkles on the polarizer. Check the front and rear three correction systems to see if they are in automatic mode. According to Coating Online, uneven lengths on both sides of the foil strip, such as when the sickle is bent too much, can cause wrinkles in the polarizer, exceeding the correction ability, so the foil material has to be replaced.
When the tension on the polarizer is too high, the polarizer will wrinkle. The tension setting value should be checked for reasonableness. Check each transmission roller again Check whether the rotation of the winding roller is flexible and promptly deal with any non flexible rollers.
9. When the back roller has inconsistent pulling strokes, the pole piece wrinkles. Mechanical maintenance personnel are required to inspect, confirm, and adjust. When the gap on both sides of the back roller and coating roller is 1mm (see the dial gauge) after they are pulled apart, trial coating should begin. When the tail is qualified, tighten the nut.
During the reuse process, the rubber roller surface of the back roller will undergo periodic elastic deformation. When there is a certain degree of residual deformation, wrinkles may also appear, and a new product must be replaced.
According to Coating Online, the loosening of the fastening screw of a certain roller caused the parallel state of each roller to be damaged, resulting in wrinkling phenomenon. As long as it is detected and adjusted in a timely manner, it can be tightened.
Four
During the operation of the coating machine, the pole piece experiences tearing and breakage
1. The tape connection is not correct, and the additional tension is increased, causing the foil tape to break at the weak point;
2. Sampling causes damage, resulting in a significant decrease in the tensile strength of the foil strip;
3. Excessive tension, instability, and sudden changes;
4. Sudden change in air volume and severe uneven distribution;
5. Sudden temperature changes have a significant impact on the strength of aluminum foil;
6. The quality of the foil strip is poor, with gaps at the edges;
7. The foil strip deviated severely and was cut off by the edge of the roller end face.
five
Other fault phenomena
1. There are obvious protrusions and scratches on the polarizer, distributed longitudinally
1) The blade of the scraper roller has gaps or foreign objects stuck to it
2) The coating roller is not easy to use. If the gap material that comes out of the coating roller is not scraped clean during the coating gap and is reapplied to the substrate, it will leave obvious marks on the substrate;
3) The parallelism between the axis of the scraper device and the axis of the coating roller exceeds the tolerance, resulting in inconsistent pressure of the blade on the coating roller, unsuitable blade shape, low blade elasticity, and so on.
2. There are obvious cracks on the polarizer
The drying speed is too fast, the oven temperature is too high, and the baking time is too long.
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