fusing machines
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FUSING MACHINES
BY-
SHEIKH KASHIF FAIZ
MAMSHI OSHIN
VASWEE DUBEY
S.P.M.E.
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FUSE-ON INTERLININGAREFABRICATIONCOATEDWITHSOMEFORMOFRESINOR
ADHESIVETHATSERVESASABONDING
AGENTTOHOLDTHEINTERLININGTOTHE
SHELLFABRIC
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REQUIREMENTSFOR FUSING
BaseCloth
Adhesives
Coating System Interlining
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Good fusible interlines must have:
Good bond strength
Good peel bond after wash
Controlled differential shrinkage
Active shrinkage and elongation through wash
and dry process
Does not get effected due to steaming
Can withstand overheat and pressure
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PHYSICAL COMPONENTSOF
FUSING
Temperature:
range from 130 to 180oC (250oF to 355oF)
Pressure : 30psi-45psi
Time :
12 to 20 seconds
Cooling under pressure
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WHATIS FUSING TEMPERATURE ?
Fusing in fact is lamination of two ore more textile
surfaces by using thermoplastic resins. Therefore
temperature is the most important factor for the
application of fusing. In the day-to-day practice
there are generally two kind of temperaturementioned:
1. the temperature suggestion of the
interlining supplier,
2. the temperature setting or reading on the
fusing machine.
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FUSINGPROCEDURE
Always ensure the fusing machine is properly heated upbefore starting bulk production every day or shift. Always testusing same bulk panels.
Interlining must be at least 2 mm shorter all around thefabric panel to be fused.
Never cut interlining larger than the fabric. This way, gluewill contaminate the conveyor belt and fabric.
Use carrier sheets while loading the fusing panels toensure that the interning panel is not moved while loading.
Fusing speed, roller pressure and temperature must becorrect as specified by supplier otherwise any incorrectstandard will result in defective poor fusing quality.
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Never use sandwich or multi layer fusing to save time. This willresult in poor fusing quality.
Machine head changed must be checked for uniformtemperature otherwise poor quality fusing will result.
If fusing by hand iron then iron must be placed firmly withweight and must not be slide across the panel.
Proper maintenance of machine is done on regular basis. Never use steam iron for using panels.
Do not blow cold air around fusing machine but rather use awell-ventilated area for good working atmosphere.
Always do testing by coordinated matching of fabric andinterlining in warp and weft direction
Interning must always be fused with interning on top of thefabric and not upside down.
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FUSINGTECHNIQUE
Single Fusing Fusible positioned on the top of the Cloth
Reverse Fusing Cloth is Positioned on the top of Fusible
Sandwich Fusing Fusing 2 components in 1 operation
Cloth on the outside, 2 fusible in the middle
Double Fusing
Fusing 2 fusible positioned one on the top of other, to the top cloth in 1operation
Top Fusing Fusible components are positioned on the top of the cloth and heat I applied
directly to the top cloth
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A FUSINGMACHINEHASDIFFERENTTEMPERATURELEVELS:
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Fusing Equipments
Flat Bed PressContinuous
Fusing Machine
Hand Iron Steam Press
High FrequencyFusing
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FLAT BED PRESS
Padded top and Bottom bucks
Heating Element in 1 or both bucks
Bottom Buck Static, Top buck can be
moved vertically
Option of Single tray and Twin tray systems Low Productivity
The three processes are Loading, Fusingand Cooling.
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CONTINUOUS FUSING PRESS
Use of Conveyor Belt as a mean of transport Synchronized belt speed
Heating plates, cylinder, rollers, and heatingzones are used
Rubber covered steel rollers to apply pressure
Air cooling and water cooling systems
Take off could be done manually or mechanically
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HIGH FREQUENCY FUSING
Multiple plies are stacked up (up to 70 mmheight) and fused simultaneously
High Productivity
Heat from high frequency energy
No shrinkage or color change
Dielectric heat: plates generate highfrequency field, heat effect is distributeduniformly in length ,width and full heightbetween platen
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HIGH FREQUENCY FUSING
Heating effect is different for differentpolymers
Adhesive is heated up faster than fabric or
interlining Time depend on capacity ofHigh
Frequency unit and weight of load to befusedo
E.g.; 30 Kw unit ; load 5-20 kg : 1-3 min Disadvantage: the press needs to be set for
fusing materials on basis of fibre, content,weight thickness and moisture content
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HOWTOCHECKTEMPERATUREANDHEATING
SYSTEMOFAFUSINGMACHINE
Most suitable for a temperature test are the well-known papermeasuring tapes.
The measured temperature between the belts (without fusingmaterial) at medium machine speed should be in accordance withthe temperature reading on the thermostat.
In case of a separate digital temperature reading it should, afterheating-up of the machine, indicate exactly the temperaturesetting.
The easiest way to test the glueline temperature is also by usingthe paper tapes.
To test the capacity and the reliability of a heating system one
should prepare a number of swatches of heavier fabric andinterlining with temperature tapes in-between, pass them throughthe machine successively and compare the results: All tapesshould show the same temperature.
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THEHEATINGCAPACITYANDTHEGEOMETRY
OFTHEHEATINGZONES
are decisive for the application of a fusing machine in view ofthe material to be fused:
Lighter material like for shirts, blouses or dresses requiregenerally lower heating capacity or shorter heating zones.
In this case the main heat should come through the face fabricside, in order to have the melting resins flow towards the face fabric.
If primarily heavier fabrics are to be fused, or in case ofsandwich
ormulti-layer fusing, higher heating capacity and a longer heatingzone is needed to make sure that the machine capacity can followthe loading speed of the operators.
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1. Heating Profiles: with specially treated surface and optimumcurvature for best belt contact
2. Heating Mat: intimately laminated to the inside of the profile
for best heat transfer
3. Sensor Position: ideally next to heating mat and belt contactsurface for quick reaction
4. Contact Surface: continuous contact with the belts forcontinuous heat flow
5. Profile Thickness: relatively thin for fast heat transfer to the beltsurfaces
6. Curved Heating Zones: for intensive contact between materialand heating surface by high fusing belt tension
7. Separate Heating Zones for optimum adjustment of thetemperature balance according to fusing method.
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The best heating system does not make sense when
the temperature control system is poorly designed.
Its functions must be fast and precise.
At any time the temperature on the belt surface must
correspond with the reading of the temperature
regulator.
There may not be any temperature swing, regardless of
the degree of loading the machine with material.
A slow reacting control system leads to unacceptable
temperature variations, whereas a fast reacting system
keeps the fusing temperature on a constantly even level
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SPECIFIC PRESSUREAND PRESSURE EVENNESS
Contrary to flat bed presses, it is almost impossible oncontinuous fusing machines, to determine the exact
pressure applied to the material to be fused.
The specific pressure is not only depending on thepressure reading on the pressure dial, but also from a fewadditional factors, such as:
hardness, thickness and surface of the silicone coating,
thickness and hardness of the material to be fused
degree of machine width coverage.
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Therefore when fusing with a machine equipped with aconventional pressure system the pressure adjustment must
be decided after fusing tests with the specific material.
A swatch of a standard part width should be used for findingout the optimum settings, considering the best possible bondstrength, surface and handle results.
Additionally it is advisable to tests the evenness of thepressure over the working width of the fusing machine.
After testing the evenness of temperature one should load themachine over the working width with several samples of the
same material combination and check the bond strength ofall samples.
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FLEXIBILITYBYDIFFERENT PRESSURE
SYSTEMS
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Single Pressure
System
* all kind of ordinaryfabrics
* outerwear mainly
* reliable and sturdy
Double Pressure
System "CU"* special treated fabrics
* dress and casual shirts
* flexible pressure range
* for all kind of interlining
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Flexo Pressure System
* for sensitive fabrics
* balancing thick and thin fabric
* soft pressure supply
* for single and sandwich fusing at the same time
* sadwich fusing
* thick and thin shell fabric at the same time*high quality fusing for outerwear
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THE CONVEYOR SYSTEM The conveyor belts are the most delicate design elements of a
continuous fusing machine. Their function, however, is crucial for theperformance of all other elements.
- They must be strong, with high tear and tensile strength.
- The surface must be smooth, to avoid marks or structure transferon delicate fabrics.
- The surface should not allow any resin adherence.- They must withstand temperatures up to 250 Celsius.
- They must be thin for optimum heat transfer.
- They may not change their dimensions when heated up.
- They must have a smooth teflon coating.
- To avoid shifting of material they must have an antistatic
treatment.- To avoid marks they should not have a thick welding joint.
- The belt edges must be sealed, to avoid fraying.
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1. Cover Belt: - endless high tech fabric
- smooth surface
- Teflon coating
2. Tracking Sensor: - for sensible belt tracking control
3. Control Roller: - gentle horizontal movement
- no over stretching of belts
4. Safety Sensor: - for additional safety
- stops machine if belt goes off
5. Belt Tensioning: - for uniform belt tension
- for intensive heat contact
6. Tensioning Roller: - for compensation of belt tension
- for centered belt tracking
7. Transport Belt: - endless high tech fabric
- smooth surface
- Teflon coating
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PROBLEMS FACED IN FUSING MACHINES
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CAPACITY
The capacity depends on material, quantity and variations offabrics and interlinings to be fused. The exact capacity canonly be calculated according to the individual situation of theparticular production.
The individual capacity calculation considers:
- all fabric and interlining parts,
- the fusing method,
- planned or actual production figures,
- daily working time or shift time in minutes,
- the individual efficiency,
- the individual cost per minute.
(- Example stated in the document)
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REFERENCES:
http://www.fusingbelts.com/all_about_fusing/all_abo
ut_fusing_on_fusingbelts.html 11-5-13 (17:50)
http://www.fusingbelts.com/Fusing%20tests/fusing
%20tests.pdf 5-5-13 (12:13)
http://www.indiantextilejournal.com/articles/FAdetail
s.asp?id=3927
5-5-13 (12:20)
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http://www.fusingbelts.com/all_about_fusing/all_about_fusing_on_fusingbelts.htmlhttp://www.fusingbelts.com/all_about_fusing/all_about_fusing_on_fusingbelts.htmlhttp://www.fusingbelts.com/Fusing%20tests/fusing%20tests.pdfhttp://www.fusingbelts.com/Fusing%20tests/fusing%20tests.pdfhttp://www.indiantextilejournal.com/articles/FAdetails.asp?id=3927http://www.indiantextilejournal.com/articles/FAdetails.asp?id=3927http://www.indiantextilejournal.com/articles/FAdetails.asp?id=3927http://www.indiantextilejournal.com/articles/FAdetails.asp?id=3927http://www.fusingbelts.com/Fusing%20tests/fusing%20tests.pdfhttp://www.fusingbelts.com/Fusing%20tests/fusing%20tests.pdfhttp://www.fusingbelts.com/all_about_fusing/all_about_fusing_on_fusingbelts.htmlhttp://www.fusingbelts.com/all_about_fusing/all_about_fusing_on_fusingbelts.html -
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THANKYOU
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