Shanghai Royal Technology Inc. is One of the top PVD vacuum coating machine manufacturers in the worldwide.We are specialize in PVD (Physical Vapor Deposition) and PECVD thin-film deposition technology and offer a range of superior coatings and equipment for various industries.
Royal Technology provides a complete line of vacuum deposition systems optimized for depositing thin film materials on complex three-dimensional substrates
We also specialize in advanced batch PVD coaters (RTEP- thermal evaporation, RTAC-cathodic arc coater, RTSP- magnetron sputtering coater, RTAS- arc+sputtering models) and ( R2R web vacuum metallizer )roll-to-roll processes that require precision deposition, tension, and uniformity. Additionally, we offer equipment and technology specifically designed for medical instrumentation and bio-compatible coatings except decorative coatings.
For Roll-to-roll (R2R) film coating machines, we have standard models as below, a customized coating plant is also available.
| Description | R2R Web Vacuum Metallizer Models | |||||
| R2R-600 | R2R-1250 | R2R-1350 | R2R-1650 | R2R-2200 | R2R-2500 | |
| Coating Technology | Thermal or Sputtering | Thermal Evaporation | ||||
| Substrate width (Max.)mm | 600 | 1100 | 1250 | 1500 | 2200 | 2500 |
| Roll Diameter (Max.)mm | 800 | 1000 | 1000 | 1000 | 1000 | 1000 |
| Core Diameter(inner)mm | 3"/6" | 6" | ||||
| Coating speed (meter/second) | 0.5 ~17, adjustable, depends on coating process required | |||||
| Coating Rollers Temperature (℃) | -20 to 25 | |||||
| Coating Chamber Ultimate Pressure(Pa) | 5*10-3 | |||||
| Pumping Speed | At the condition of without loading, clean, room temperature: less than 8 mins, from atm to 7*10-2 | |||||
| Pre-treatment Tool | Linear Ion Source | |||||
| Deposition Source | BN Crucible or Planar/Rotary cylinder sputtering cathode | |||||
| Deposition Material | Al, Al,Cr,Cu,Ni, NiCr, Stainless Steel, Ti, | |||||
| Working Environment | Power:3Phase, 5wires, 380V±10%,50Hz/60Hz | |||||
| Cooling water: EDI, 4~6 Bar @25℃ | ||||||
| Compressed air: 5~6Bar, filtered and dried | ||||||
R2R(Roll-to-Roll)web aluminum vacuum metallizers are machines used in the manufacturing industry for depositing a thin layer of aluminum onto flexible substrates in a continuous roll-to-roll process. This process is widely employed in various industries, such as packaging, electronics, automotive, and decorative applications.
The R2R web aluminum vacuum metallizer typically consists of the following components: Unwind Station, Cleaning Section, Pre-Treatment Section, Metallization Chamber, Cooling Section and Winding Station.
R2R web aluminum vacuum metallizers offer many advantages, such as high production speeds, excellent control over the thickness and uniformity of the aluminum layer, and the ability to process a broad range of flexible substrates. These machines are essential for creating functional and decorative coatings on materials like plastic films, paper, foils, and textiles.
It’s worth noting that particular details and features of R2R web aluminum vacuum metallizers may vary based on the manufacturer and the intended application.
The RT-R2R Web Aluminum Vacuum Metallizer is designed to provide high throughput capabilities, which help to reduce production costs. The system also provides a heavy deposition layer for high barrier applications. Additionally, by using a free-span process, the need for a drum line and material trim is eliminated. Other features include a friendly operation for lower tension substrates, including CPP, BOPP, and LDPE, individual wire feeds, easy maintenance, and precision web handling mechanisms. It also features a compact design, which allows for easy installation and minimal floor space.
Royal Technology provides FREE-SPAN and DRUM SUPPORTED deposition systems to satisfy different coating process demands.
The process of R2R (Roll-to-Roll) web vacuum metallizing involves depositing a thin layer of metal, typically aluminum, onto a flexible substrate in a continuous roll-to-roll manner. Here are the key steps involved in the process:
Substrate Unwinding: The process begins with a roll of the flexible substrate material, which is unwound and fed into the metallizing machine.
Cleaning and Pre-Treatment: The substrate may pass through a cleaning section to remove any surface contaminants that could affect the adhesion of the metal coating. Following cleaning, the substrate may undergo pre-treatment processes such as corona treatment or primer application to enhance the bonding between the substrate and the metal layer.
Metallization Chamber: The heart of the R2R web vacuum metallizing equipment is the metallization chamber. The substrate enters the chamber, which is maintained at a high vacuum. The chamber typically consists of a series of evaporation sources or cathodes, which contain the metal (such as aluminum) to be deposited.
Metal Evaporation: The metal within the evaporation sources is heated to its evaporation point. As the metal evaporates, it forms a vapor cloud within the chamber. The vaporized metal atoms travel in straight lines and condense onto the moving substrate, forming a thin, uniform metal layer.
Substrate Cooling: After the metallization process, the coated substrate passes through a cooling section, where the metal layer solidifies and stabilizes.
Substrate Winding: Finally, the metallized substrate is wound onto a roll, ready for further processing or use in various applications.
It's worth noting that the specific details and parameters of the R2R web vacuum metallizing process can vary depending on factors such as the desired metal coating, substrate material, and intended application. The process can be optimized to control factors like coating thickness, adhesion, and uniformity to meet specific requirements.
R2R web vacuum metallizing offers advantages such as high production speeds, precise control over coating thickness, excellent adhesion, and the ability to process a wide range of flexible substrates, making it a versatile and widely used technique in industries such as packaging, electronics, automotive, and more.
Vacuum Web (Roll) Coating is a process of coating a thin and flexible material that is in the form of a roll. This roll of material can have a width of several inches to 10 feet, a length of tens of thousands of feet and can weigh thousands of pounds. The coating speed of these rolls can go up to 2000-3000 feet-per-minute. This process is usually conducted in a vacuum. Figure 1 shows a typical roll coating system with thermal evaporation being used for deposition.
R2R (Roll-to-Roll) web vacuum metallizing equipment has a wide variety of uses in numerous industries. To begin with, vacuum metallizing is employed extensively for packaging materials in order to improve their visual appearance and functionality. It can be used for flexible packaging, such as candy wrappers and pouches, in order to provide a glossy, metallic appearance and to improve their barrier properties. Additionally, vacuum metallizing finds employs in decorative applications for industries such as automotive, electronics and consumer goods. Furthermore, reflective coatings are produced with vacuum metallizing for products such as mirrors, reflective films and reflector covers for lighting fixtures. The reflective properties of metallized coatings help to improve light reflection and the efficiency in optical systems.
Moreover, vacuum metallizing is utilized to make conductive coatings and EMI/RFI shielding for electronic components such as touchscreens, flexible circuits and printed circuit boards. Furthermore, metalized coatings are applied to solar mirrors used in Concentrated Solar Power (CSP) plants in order to increase sunlight reflectivity and hence, optimize energy capture. Lastly, metallized coatings are utilized in banknotes, labels, and packaging to prevent counterfeiting.
This is only an overview of the many applications of R2R web vacuum metallizing equipment. As a result, a wide range of possibilities in terms of functional and decorative coatings on flexible substrates exist.
At Roll To Roll Coating Machine, we understand that our customers need reliable technical support and service to get the most out of their machine. That's why we offer a comprehensive range of services to make sure your machine remains in top condition and you get the most out of your investment.
1.Our trained technicians provide on-site technical support and offer preventative maintenance services to help you avoid potential problems.
2. We can help diagnose technical issues, advise on the best path to take to resolve them, and provide the most cost-effective solutions.
3. We also provide replacement parts and components, as well as expert advice on installation and operational procedures.
4. We also offer remote support and online troubleshooting tools to help you with any technical issues you may have. Our online support system is available 24/7 and provides easy access to technical advice and product documentation.
5. We strive to provide the highest level of customer service and technical support. Our goal is to ensure that you have a seamless and enjoyable experience with your Roll To Roll Coating Machine.
