Technologies and Services

Film Casting Machine

Steel Belt Film Casting Machine Optimal for Film Forming Process of the Dissolution Flow Casting Method

Technologies and Services
Film Casting Machine

This machine forms TAC, PI, PP, PVC, PC, and PVA films using the dissolution flow casting method. Since this machine uses an ultra-mirror polished steel belt, it can be applied to the production of high-quality optical films. Based on design, knowledge, know-how, and simulation analyses learned from years of experience, we offer machines with optimal specifications to suit your needs.

Advantages and Features

1Provision of ideal machines for optimum manufacturing of delicate optical films

2Accomplishment of high-speed operation to improve productivity

3Analyses by simulations and optimization of the design of machines by applying the analyses results

4Provision of different film production lines by our total engineering services

1. Provision of ideal machines for optimum manufacturing of delicate optical films

The film casting machine (single belt casting machine) forms the films by applying resolved raw material (dope) onto the rotating steel belt and drying the dope with hot air. The machine has a high-precision gear pump to supply the dope, a specially designed T-shaped die, and an ultra-mirror polished steel belt designed for high precision in the thickness of the cross direction. With these components, high-quality films of uniform thickness can be formed, and excellent surface smoothness can be achieved by mirror transcription. We offer machines ideally optimized for the production of optical films.

2. Accomplishment of high-speed operation to improve productivity

To improve productivity, an increase of operational speed is essential. Speeding up the operation requires such contrivances as the extension of the lives of the steel belt and other components and control of the position of the belt. With our original mechanical structure, control system, and analysis technology, we actualize excellent control of the position of the belt even when the length of the belt exceeds 100 m. We can offer a high-speed film casting machine whose production speed reaches 100 m/min.

Machine Specifications
1	Belt width	~3000㎜
2	Belt length	~160mL
3	Production line speed	~130m/min
4	Temperature	~150°C(Non-explosion proof)
5	Film width	~2940㎜
6	Film thickness	(10㎛)~

3. Analyses by simulations and optimization of the design of machines by applying the analyses results

We execute simulation analyses to validate the relationship between film production and the specifications of the machine and design the machine optimally.

Hot Air Simulation Analysis

The airflow from the hot air outlets (from the chamber) inside the machine is analyzed to optimize uniformity of the airflow and the specifications of the shape of the outlets.

Before Improvement

The analysis of the current conditions revealed that the airflow above the belt is disturbed.

After Improvement

By making the airflow uniform in the feed direction of the product, the air above the belt flows uniformly.

Film Drying Simulation

Support for the measurement of the coefficients of the physical properties of the dope (raw material).
Analyzing the drying conditions of the film on the steel belt in a simulation helps us optimize the specifications of the steel belt length and drying temperature.

4. Provision of film production lines by our total engineering services

We offer production lines with high productivity and stable quality using a variety of technologies necessary for film production, including raw material feeding technology, film production technology, inspections, and product handling technology.

Possession of element technologies to construct production lines

We offer a set of production lines with high productivity and stable quality (which leads to the development of new products, an increase in production, and improvements in productive efficiency).