innovative method to manufacture pvc electrical insulation tape
DESCRIPTION
We have Invented a Method to Manufacture PVC Electrical Insulation Tape , by using Water Borne Acrylic PSA , or Hot Melt PSA. This a very economical manufacturing method. Please contact us if you are Interested. Best RegardsTRANSCRIPT
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By Shrikant Athavale
Prathith Consultants
Pune – 411038
www.psadhesive.com
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Here is a Innovative method of Manufacturing Self adhesive Tapes . This method is exclusively developed for handling Temperature sensitive Films, mechanically weaker substrates like PVC Film ,non woven , lower GSM papers , foils , foam etc.
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A Innovative method of manufacture of
/ Non Woven fabric based Surgical tape , which has
maximum sale , in Indian Market , which is used for
Domestic Electrical Insulation purpose. Allmost 70% of
the total requirement of this tape is Imported from China ,
because it is viable at very cheaper price as compared to
the Indian manufacturers product. Hence there is a big
scope to manufacture this product , locally , at a very cost
effective price , and explore the market m and to put an
break to the Import of this product.
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1. Very cost effective 2. Lot more easy to operate and with faster
processing speeds 3. No Heat treatment required , for Log rolls 4. Will reduce wastage to a great extent. 5. Require much lower Heat energy . 6. Retain of Mechanical properties. 7. Saving in the Capital cost. 8. Flexibility to use , differ kinds of PSA’s.
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Very cost effective ?
Faster processing speeds Lower wastage Requires much lower Heat energy for processing No Primer coating No Chilling Retain original Mechanical properties Lower Capital Investment Require less space , to Install The flexibility to use , differ kinds of PSA’s.
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Lot more easy to operate and with faster processing speeds
The newly designed machine will be lot more easy to operate and with faster processing speeds
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Will reduce wastage to a great extent.
The invented process will reduce wastage to a great extent.
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Require much lower Heat energy .
The new processing method , will required much lower Heat energy for processing , due to the Innovative design , some existing processes like Primer coating, Coated Film Chilling etc. will be totally eliminated
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Retain of Mechanical properties.
The PVC Film/ Non woven Fabric will retain its original Mechanical properties , because it is never exposed to the Draying Heat , a most crucial requirement in the existing Process.
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Saving in the Capital cost.
There will be a lot of saving in the Capital Investment , since the Machine is very much compact than the existing one , it will require less space , to Install, and the electrical energy consumption , will be reduced almost to 50% of the existing Procedure/ process.
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Flexibility to use , differ kinds of PSA’s.
One more advantage is , the flexibility to use , differ kinds of Pressure sensitive Adhesive. At the moment , with the existing technology , only Solvent based Rubber adhesive is permissible to use , due to the limitations , built in the process itself. With the Invented method , there will be a choice to select adhesive , which can be , Water Based, Solvent Based (Prevailing ) , or Hot melt , Adhesives.
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Description of the Invention
The Invented process of manufacturing the PVC Tape / Surgical Non woven , paper Tape , is very simple. This method is generally termed as transfer Coating method. In this said process The Silicone Release Coated paper / Film is coated , with adhesive , and then dried , if it’s water base or Solvent base , and the same is laminated with the PVC Film at the Lamination station . In case if Hotmelt adhesive is used than there is no question of drying at all , since the adhesive do not contain any solvent. Once the film is laminated with the adhesive coated Silicone paper , The laminate moves towards the Rewinding station. Here the Silicone paper is delaminated from the film , and the same is rewound on a separate Shaft. However the Film which is now adhesive coated and delaminated w, from the silicone paper is , wound on a separate rewind shaft , equipped with 4 station turret
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The PVC / Non woven fabric is carona treated , ( prior to lamination with Silicone Paper) , which is a mechanical process only , and requires no extra raw materials , like Rubber based primer , ( Dissolved in solvent ) , The film is also treated with a release coating , for easy unwinding later on , the release coating is entirely based on water based system. The machine sketches for both , the existing process , as well as the Invented process , are attached for ready reference.
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The PVC Tape , mainly used for , low tension , Domestic , Electrical Insulation , is manufactured as follows. PVC film is coated with , a Rubber based primer in solvent solution form , with approx. 2.5 gm / sq. mtr of coating ( Dry Wt. ) , on a Gravure coating machine , then it passes through a drying tunnel to evaporate the solvent . The Primed Film is then , coated with a Rubber Based ( Solvent dissolved ) Adhesive , on a comma coating station, with a coat weight of approx. 90 gm/ sq. mtr ( Dry ) , and then it is passed through the drying tunnel , to evaporate the solvent. The dryed file is then passed through the Freezing Tunnel , to cool down the film to room temperature , so that the in built stresses are relaxed.
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The cooled film is then rewound into rolls on a turrent Rewinder , to make rolls of exact length in meters. The tape log rolls as produced above are method is then conditioned at elevated temperature of around 48 deg C for a minimum period of 18 hours , for further stress relaxation process. The rolls conditioned as above are then sliced into , required widths like , 18 / 24 mm as per requirement , and then packed and are ready for sales.
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PVC Film Primer
Primed PVC Film
Primed PVC Film RubberBased Adhesive
Adhesive coated PVC
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Conventional Machine Design for the Manufacture of PVC Tapes
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Our Invention is so different form the existing process , and the same is as follows. With the Invented method there is a choice of selection of Adhesive system . The is substantial saving , if Hotmelt adhesive is used , as the adhesive coating weight , is reduced from 90 gm/ sq. mtr. To mere , 35 gm/ sq. mtr . By using , the specialy compounded Water base adhesive , the cost is reduced considerably , due to the fact that this adhesive will be atleast 25% cheaper than the Solvent based one. Secondly the Water based adhesive is totally environmentally friendly , and hence there are no VOC related issues.
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One more major cost reduction is due .Thanks to the Newly Invented Process , where there No Primer used at all. The priming process is done , based on a Electro mechanical method called Carona Treatment, For this treatment , no raw material is consumed , and the electrical energy consumption is very much on lower or is negligible The process is very simple and there is another advantage , also in built. Since the film is not exposed to Heat , there are No in built stresses , and the film retains it’s original Mechanical properties. Since , there are No in built Stresses , the Annealing or conditioning process , is totally eliminated , which is a must for the existing way of this tape manufacture .
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The equipment is far more cost effective , requires much lower capital Investment , lower Shop floor area for manufacturing, lower electrical energy consumption, much lower coating of adhesive , no primer coating . All the equipment can be are manufactured in India as per our machine design. The complete Machine sketch is attached for ready ref.
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PVC Film
CARONA tREATMENT
Carona PVC Film
Rubber Based AdhesiveAdhesive coated PVC
PVC Film
Carona PVC Film
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Innovative Machine Design for PVC Tape With Hot melt PSA
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Innovative Machine Design for PVC Tape With WB PSA
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For more details on the machine design, Adhesive Formulations, especially for Water Borne PSA for these tapes contact us on Email : [email protected] Or Mobile : 09850242282 /07588288204 Or Visit us on : www.psadhesive.com
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