Roll-to-roll coating machines are designed for continuous coating of flexible substrates (e.g., films, foils, fabrics). Their core features revolve around "high efficiency, precision, and versatility" to adapt to mass production of flexible materials:
- Wide Material Compatibility: Supports coating on various flexible substrates, including PET (polyester film), PI (polyimide film), metal foils (aluminum foil, copper foil), non-woven fabrics, and thin glass (thickness ≥ 0.1mm).
- Adjustable Substrate Width: Compatible with roll widths from 300mm (laboratory scale) to 3200mm (industrial large-scale), meeting needs of small-batch R&D and mass production.
- Tension Stability Control: Equipped with a multi-section intelligent tension control system (tension range: 5 ~ 500 N), avoiding substrate wrinkling, stretching, or breaking during unwinding, coating, and winding.
- Non-Stop Operation: Integrates unwinding → pre-treatment (plasma cleaning/heating) → coating → drying/curing → winding into a single line, supporting 24/7 continuous production (downtime ≤ 1% for roll replacement).
- Fast Coating Speed: Coating speed adjustable from 1 ~ 15 m/min (depending on coating type and thickness), e.g., 8 m/min for 5μm-thick adhesive coating on PET film.
- High Material Utilization: Precision coating heads (e.g., slot die, gravure) reduce material waste to ≤ 5% (far lower than batch coating’s 15%+ waste rate).
- Uniform Thickness: Coating thickness range 0.1μm ~ 500μm, with thickness uniformity error ≤ ±3% (achieved via real-time thickness monitoring systems like laser sensors or beta gauges).
- Multi-Coating Technology Compatibility: Supports slot die coating (high precision for functional films), gravure coating (high speed for decorative layers), Mayer rod coating (low cost for thin layers), and spray coating (for irregular surfaces).
- Stable Curing/Drying: Configurable with hot air drying, infrared (IR) curing, or UV curing modules (temperature control accuracy ±1℃), ensuring coating adhesion and performance.
- Automated Control: PLC + HMI touchscreen system, with one-click recipe storage (supports 100+ coating parameters), automatic fault alarm, and remote monitoring (optional IoT function).
- Environmental Compliance: No volatile organic compounds (VOCs) for water-based/UV coatings; waste gas treatment systems (optional) meet EU CE and US EPA standards.
- Space-Saving Layout: Horizontal inline design (length 5 ~ 20m, customizable) reduces floor space by 30% compared to traditional multi-machine batch setups.
Focus on solving industry pain points (low efficiency, poor consistency, high cost) and highlighting competitive advantages for target customers (flexible electronics, packaging, new energy industries):
- Eliminate Batch Coating Limitations: Replaces "cutting → single-piece coating → splicing" with continuous production, reducing production cycles by 60% (e.g., 10,000㎡ PET film coating takes 1 day vs. 3 days for batch processing).
- Improve Product Consistency: Avoids manual operation errors in batch coating; ensures uniform thickness and adhesion across the entire roll (critical for flexible circuits and solar films).
- Reduce Labor Costs: Full-line automation requires only 1 ~ 2 operators (vs. 5 ~ 8 for batch coating lines), cutting labor costs by 70%.
- Low Operating Cost: High material utilization (≤5% waste) + energy-saving motors (15% lower power consumption than similar models) + low maintenance (wear parts have 5,000-hour service life).
- High Return on Investment (ROI): Industrial-scale machines (1600mm width) can recover costs in 8 ~ 12 months (based on 8-hour daily operation for flexible packaging films).
- Scalability: Modular design allows adding pre-treatment (plasma) or post-processing (slitting) modules without replacing the entire machine, adapting to business growth.
- Multi-Industry Adaptation: One machine for multiple applications (e.g., adhesive tapes, flexible OLED films, lithium-ion battery separators) by switching coating heads and recipes.
- International Quality Standards: Coated products meet ISO 9001 (quality), RoHS (environmental), and UL (safety) standards, supporting export to global markets.
- Customization: Offers custom solutions for special needs (e.g., anti-static coating for electronics, high-barrier coating for food packaging).
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4. Key Technical Parameters
| Parameter Category |
General Range |
Description |
| Substrate Width |
300-2000mm |
Customizable width according to requirements |
| Substrate Thickness |
10μm-500μm |
Adaptable to different flexible substrate thicknesses |
| Coating Material |
Metals, alloys, oxides, etc. |
Matching corresponding target materials is required |
| Coating Thickness |
5nm-5μm |
Adjustable via sputtering power and speed |
| Vacuum Degree |
1×10⁻³ - 5×10⁻⁵ Pa |
Ensures sputtering quality and coating purity |
| Production Speed |
0.5-5m/min |
Adjusted based on coating thickness and substrate characteristics |
5. Equipment Composition (Core Components)
A complete set of equipment usually includes five systems to ensure stable operation:
1. Vacuum System: Composed of a vacuum pump set (molecular pump, roots pump) and a vacuum chamber, it maintains the high-vacuum environment required for sputtering.
2. Magnetron Sputtering System: Includes magnetron targets (planar targets, cylindrical targets) and sputtering power supplies (DC, RF), which are responsible for generating coating particles.
3. Winding and Transmission System: Consists of an unwinder, winder, guide rollers, and tension control system, ensuring stable and continuous transmission of the substrate.
4. Temperature Control System: Equipped with chamber heating/cooling devices and substrate temperature control modules to prevent substrate deformation due to high temperatures.
5. Control System: Adopts PLC + touch screen to realize automatic control and monitoring of parameters such as vacuum degree, sputtering power, and transmission speed.
