LAMINATOR TOUR Cold Roller Components

Cold Roller laminators are used for the overlaminating using pressure-sensitive films and applying pressure-sensitive mounting adhesives. There are any number of cold roller laminator models available, but they all share certain common components. Illustration 4A in the margin demonstrates the basic functions of a cold roller laminator. 1. Main Rollers 2. Film supply or unwind shaft. 3. Liner take-up roller 4. Idler bar In Illustration 4A, the pressure-sensitive overlaminate film has been loaded onto the Film Supply Shaft (2). The film path runs past the idler bar (4), where the release liner is separated from the film and wound onto the Liner Take-Up Roller (3). The pressuresensitive film itself is wound onto the top Main Roller (1). When the rollers turn, the pressure-sensitive film contacts the graphic as the graphic passes into the Roller Nip. The pressure of the rollers activates the adhesive on the film, bonding it to the printed graphic.

IN THIS SECTION: LAMINATOR TOURS

COLD ROLLER MULTIHEAT HOT SHOE

LAMINATOR SETUP
LOADING ROLLS WEBBING TECHNIQUES FEEDING FILM CLEANING AND MAINTENANCE

Controls A typical cold roller laminator is equipped with the following controls: 1. Main roller speed control 2. Roller pressure setting 3. Supply unwind tension brake Tutorial 1:
SINGLE-SIDED LAMINATION

Multi-Heat Laminator Components & Features

A multi-heat laminator is the most common type of finishing processor found in shops with volume mounting and laminating requirements. Multi-heat laminators can be used to process Although there are wide variations in configuration and features, Illustration 4B shows the major components of a typical, full-featured laminator.

1. Main Rollers 2. Supply unwind shafts 3. Take-up shaft 4. Idler bars 5. Pull rollers 6. Infeed table 7. Outfeed table 8. Lower takeup shaft 9. Chill bars/cooling fans COMPONENT DESCRIPTIONS MAIN ROLLERS: The upper and lower main rollers deliver the heat and pressure that facilitates bonding of the adhesives. The feed speed of the rollers controls the dwell time, which is the amount of time the components of a graphics system are in contact with one another. The hardness of the main rollers is a factor in the dwell time and also affects the actual delivered pressure at the nip. The diameter of the rollers also affects dwell time and delivered pressure (see 4C). The mail rollers may also be flat or crowned, meaning that the roller shape tapers to a slight rise in the center. Generally, crowned rollers deliver a more uniform pressure across the nip contact points. SUPPLY UNWIND SHAFTS: Most heavy duty laminators are equipped with two or three supply shafts. Rolls of overlaminate or mounting adhesive are loaded onto the unwind shafts and webbed to the Main Rollers for processing. Printed graphics on rolls may also be loaded onto a supply shaft for laminating or encapsulation. The brake on the unwind shaft is a key operating control because it affects the tension on the web. Too much tension can cause several types of laminating failure. TAKE UP SHAFTS: Rolls up release liner from pressure-sensitive or heatset laminating films. May also be used to roll up finished graphics or carrier sheets. IDLER BARS: These metal shafts are used to create tension on films in the web and to control the separation of films and release liners. PULL ROLLERS: Located at the rear of the

laminator, pull rollers are used to help control distortion of thermal films as they cool. The are usually disengaged for pressuresensitive and heatset jobs. INFEED TABLE: Used to line up and load supported or insupported graphics into the roller nip. Some infeed tables are equipped with jigs that accommodate roll fed graphics from lower supply shafts. CHIIL BARS/COOLING FANS: Used to accelerate the bonding in thermal and heatset films, chill bars essentially increase the cooling distance during which the finishing components are in contact. Go to Section 5 for more information on this subject. OTHER IMPORTANT FEATURES The following is a list of important features that differentiate performance among different models of Multi-Heat Laminator. Single Heat vs. Dual Heat Some roller laminators are equipped with a single heated roller, while most have dual heat rollers. Dual heat rollers are preferred for increased control and set-up flexibility. Pneumatic vs mechanical pressure Laminators deliver pressure to the main roller nip in two ways: pneumatically and mechanically. In general, pneumatic pressure is preferred to mechanical pressure because the pressure is delivered more uniformly and is more controllable. Pneumatic equipment allows the operator to change pressure settings during processing, which mechanical laminators do not. This subject is discussed in more detail in Section 5. Image transfer capability Some higher end models are capable of electrostatic image transfer. Typically, these laminators have larger rollers and are able to deliver the sustained dwell times and high temperatures necessary to facilitate the transfer process. On to Section 5: Fundamentals of Operation

SINGLE-SIDED LAMINATION with PRESSURE-SENSITIVE (Cold) FILM

This tutorial describes the application of a pressure-sensitive overlaminate film to one side of a graphic that has already been mounted to a rigid substrate. This procedure also works for unmounted graphics, which are placed on a rigid "sled" or carrier board prior to processing. For more on the topic of using a sled, go here.

TE CH HE LP DIR EC TO

RY

Settings
TEMPERATURE: Pressure-sensitive films do not require heat to bond, however, many will benefit from the application of lower temperatures at the Main Rollers. Do not exceed 120 F degrees. MAIN ROLLER SPEED: 1 - 6 ft / min. Some more rigid films benefit from slower speeds. See manufacturer's recommendations. PRESSURE: 30 to 60 psi (varies according to machine). PULL ROLLERS: Up. Set the gap to accommodate the thickness of the mounting substrate or sled. See Section 4 of the Textbook for more training in laminator set-up and webbing techniques.

Procedure
1. Load a roll of pressure-sensitive overlaminate film onto the Upper Supply Unwind Shaft with the

lead film edge facing up. 2. Unwind the film and bring the edge underneath the Idler Bar. 3. Separate the release liner from the film and attach it to the Upper Take Up Shaft. 4. Handling the edges of the pressure-sensitive film, bring it over the top of the Upper Main Roller and position is squarely on the roller. Go to Section 4 for more on laminator setup and webbing techniques. 5. Use a Leaderboard to push the hanging film into the nip of the Main Rollers until it is wrapped tightly and evenly around the top Main Roller. Then turn on the Main Rollers and process the leaderboard through the rollers. Stop the machine when most of the leaderboard has passed through, and only 1/2 to 1 inch of the board is still exposed. 6. Push the mounted graphic or sled up to the edge of the leaderboard and butt it up against the back of the leaderboard. Turn on the Main Rollers and process the mounted graphic or sled through the rollers. 7. When the graphic has passed through the rollers, cut the web of the film behind the idler bar using a "zippy blade" or similar safety knife. Do not stop the laminator until the graphic has passed completely through the rollers. 8. In order to take up the extra film that will pass through the rollers after cutting, use either a second leader board or cut off the first leader board and re-insert it into the roller nip. TIP #1: Make absolutely certain that the leaderboard and the mounting substrate/sled are the same thickness. TIP #2: Adjust the Take Up Shaft speed so that the release liner is pulled away from the film just before it makes contact with the Main Roller. This procedure minimizes the time the adhesive is exposed to the air, and helps reduce dust and stuff. Take me to Tutorial #2. Copyright 2006 by Drytac Corporation - All Rights Reserved

The Four Key Variables

Although there are many types of mounting and laminating operations, they are controlled by four variables: 1. Time 2. Temperature 3. Pressure 4. Humidity An understanding of these variables allows you to setup and adjust your equipment and procedures for the best possible results. Each of these variables is discussed in detail below.

IN THIS SECTION: FOUR KEY VARIABLES

TIME TEMPERATURE PRESSURE HUMIDITY

SETTINGS
START-UP MAKING ROLLERS PARALLEL WEBBING TECHNIQUES CLEANING AND MAINTENANCE

Time
The TIME variable in laminating and mounting is defined as the duration of the contact between the adhesive and the printed graphic, as applied at the roller nip. In terms of operator control, this variable is

related to the feed speed of the rollers. Slowing the feed speed on the laminator increases the time of contact. This step would be necessary, for example, when laminating over high ink coverages in order to provide more time for bonding. This discussion continues in more detail below. See margin for trouble shooting links for more on time related topics.

Temperature
TEMPERATURE is a key operating parameter for thermal and heatset films as well as mounting adhesives. Whatever type of equipment is in use, it is necessary to raise the temperature of the adhesive to its correct bonding threshold. However, the true effective temperature is not always easy to determine. For a complete explantion of the factors involved in determining temperature accuracy during processing, go to the Temperature Accuracy discussion in Section 9. Each of the three types of films bonds in a different temperature range. Thermal films generally operate in a 185 to 240F range. HeatSet or heat assist operate in a 185 to 210F range. Pressure sensitive films do not require heat for bonding, but often benefit from additional heat (up to about 120F). Exceeding recommended temperatures can cause distortion in an overlaminating film. Failing to reach the temperature threshold for thermal or heatset films will prevent proper bonding.

Pressure
An increase in PRESSURE magnifies the effects of both time and temperature. On a laminator, pressure is delivered at the roller nip and is a key operating parameter for thermal and heatset films and adhesives. Pressure may be created either mechanically or pneumatically, depending on the laminator. Mechanical pressure is created through the use of springs, gears and the weight of the rollers themselves. Pressure is usually set using a handcrank. Mechanical pressure is usually associated with lower Illustration 5A: Effects of Time, Temperature and Pressure

Time Related Trouble Shooting

Inkjet Related Problems Silvering Boat Wake

cost laminators because it is less reliable. Pneumatic pressure is generated using an air compressor. Pressure gauges are used to indicate pounds per square inch (PSI). The pressure gauge shows the PSI at the main cylinder (that is, how hard it is pushing on the rollers) but not the effective pressure. Pressure is one of the most difficult laminating factors to measure and control. Actual pressure may vary from the air pressure indicated on the control panel. The two most important addition factors affecting "real" pressure are: The outside diameter of the rollers The hardness of the roller surface The combination of these two factors dictates the total area of contact at the nip. Given the same level of pressure applied by the laminator to the rollers, the read pressure at the nip will depend on the area over which it must be spread. Rollers with greater diameters mean more contact area, which in term reduces effective pressure. Softer roller surfaces increase the contact area and reduce effective pressure.

Humidity
The amount of humidity in a shop environment can affect the performance of finishing jobs far more than most operators realize. The level of humidity can affect the amount of time it takes for a screen printed or inkjet print to dry, which in turn can result in moisture being trapped between the film and the print. Allow sufficient time for prints to dry. Maintain relative humidity of 20 to 80 percent Store media and laminates properly Allow time for acclimation of media and laminates Use a dryer or fan on printed graphics On to Section 6: Finishing Applicatiopns