incredible archipelagos of applications
Web material as cigarette, tipping, roll-your-own RYO paper, regenerated cellulose films, filter, transparent, coated special, bag or packing papers, bonded fabrics, spun bonded non-woven, technical textiles, fabrics, laminate, etc. with base weights from 20 g/m2 to up to 150 g/m2, up to 20 g/m2 LPDE coating films, are perforated electro statically ESP nano, micro, laser or mechanical (micro or hot needles) micro or macro for a wide range of application purposes.
For a better comprehension: electrostatic NANO MICRO PERFORATION, based at micro discharging, Bluemlein as well as tunnel effect with plasma gas atomic generation and expansion, are statistically irregularly distributed, size from 0.1 up to 120 μm diameter and analogically, under LASER or micro macro mechanical PERFORATION, arranged in diameter sizes from 60 up 200 μm, at best non-inclined holes und rows of holes of diverse arrangement.
For the human eye invisible electrostatic nano or micro perforations may be arranged in areas as well as in zones with specific distances within its web. The sizes of the holes range from 0.1 to 120 µm in diameter and hole sequences from 1.5 to 16 million pores per second. Arrangements of zones are usually carried out in width from 2 to 6 mm and pore density of 15 to 250 pores per cm2 whereas the perforation of areas results in pore densities of up to 5 million pores per m2. ESP perforations allow porosity levels from 80 to 2500 C. U., web widths from 100 to 2000 mm at web speeds of up to 500 m/min, depending on porosity and material consistency in relation to its ability to perforate.
Conventional laser perforation
Possible to perforate by pulsed or enlarged and focused laser beams are holes sizes from 60 to 200 µm at density of holes of typical 10 to 30 holes per cm, holes sequences from 100.000 to 500.000 holes per second at a maximum of 32 hole rows by laser distributed over the width of the web with traditional systems or machine. Their porosity levels range from 100 to 3000 C. U., normally with web widths from 100 to 500 mm at web speeds of up to 600 m/min, depending on the porosity and material consistency in relation to its ability to perforate.
IPM laser perforation processes
IPM owns development of LASER PERFORATION technology LPM-1 (patent grand DE102004001327) operates with quadruple laser beam inputs of 8 KW optical power to a double level beam multiplexer to generate up to 200 individual laser perforation rows across the web, combines automatic laser perforation head positioning, focus setting, web speeds up to 400 m/min, web widths up to 2000 mm, up to 4,000.000 holes per second, jumbo-roll-by-roll production, optical online permeability and perforation line positioning control, porosity feedback and other features. Each laser perforation lines are archive able from 100 up to 2000 C.U.
Industry areas
The conception of high power laser beam multiplexers enable many possibilities in other industry application fields as cutting, cut-offs, welding, surface finishing, drilling, polishing, forming, surface treatment, roughness improvement, etc.
Each of the 200 single perforation head can be positioned across the running web or static positioned material. The automatic processes, equipments and devises opening completely new possibilities in industry, science, military or space laser application. Patent grant of process and device with DE102004001327.
Further laser features
A patent pending Micro Laser Line perforation technology MLL-1 generates sinus, waves, zigzags or other kinds of perforations cryptograms, designs as multiple or quadruple pairs of micro laser lines in web direction. Provide for tipping, cigarette, packaging or other kind of paper or material webs.
Special features of micro laser line perforation enables fundamental new product characteristic in scripts, e.g. for mouthpieces with tipping paper CTP on cigarette filters, product indication with visible perforation holes, brand name, company logo, indications, anti counterfeiting designs, cryptogram, etc. As well is that process to use by other material, industry and application field. Patent pending for process, device and product property DE102004012081.
Ventilation of filter cigarettes
Electrostatic perforation has been used since 30 years for ventilation of non filter, RYO or filter cigarettes to create a directed and guided air bypass or Lindstroem principle. For this purpose, cigarette paper for some non filter cigarettes and almost every kind of filter cigarettes tipping papers are perforated electro statically OFFLINE in zones from 2.0 – 6.0 mm width or rows ONLINE or OFFLINE by use of slow, fast flow or sealed-off CO2 laser in order to reduce the harmful substances such as nicotine and condensate down to allowed values. Another effect is the possibility of guiding and controlling the degree of ventilation of the Cigarettes.
Product properties with electrostatic perforation
One of the foremost postulation which can be applied to many application purposes and products containing bonded fabrics, bag or packaging papers, non-woven, etc. with gas or steam permeability but water impermeability will be found at the application stage of the ELECTROSTATIC NANO MICRO PERFORATION TECHNOLOGY. Which means pore sizes from 0.5 up to 10 µm diameter by up to 5 million per m2. This is due to the water’s greater surface tension through the relatively small nano or micro pores. These and other physical advantages of the pores necessarily demand the application of the ESP perforation method because alternative perforation or processes are NOT feasible, too expensive or simply uneconomical and would not lead to a successful application.
To archive new ESP demands IPM developed new electronic perforation circuits which working as upward converters with IGBT’s, MOSFETS’s or HVFET’s for power pulses from 1 µs up to 25 µs, high current peaks up to 300 Amps, base frequencies up to 200 KHz on ferrite transformers to generate 50 Kilovolt to each sparking electrode.
Patent grant DE10328937 of IGBT power switching units.
Online porovision control
Since naturally porous web materials or web materials to be perforated are processed with speeds of up to 600 m/min and web widths of up to 2000 mm are used, a pneumatic porosity measuring, hence measuring whilst touching the web are highly difficult. Further difficulties of pneumatic measurements are the disadvantages of rising of web tension, material abrasion, folding, leakage at measuring head, impurities, non linear processing and calibration problems.
Thus, optical measuring offers better ways for transmission measuring the pneumatic static permeability for naturally porous or nano, micro or macro perforated webs. The conditions mentioned above can be easily met by using the optical porosity measuring technology thanks to the mentioned product processing and online control, extremely small pore dimensions, relatively high track speeds and a good value repetition.
That full independent from principle material facts as consistence, thickness, weight, coloring, formation, smoothness, brightness, opacity, and other influences.
Patent pending for process and device DE10251610 -
Therefore, IPM – International Perforation Management – has developed a number of new, patent pending, stationary and transverse optical measurement processes and systems which working with multiple color sensors, a precision line laser, scanning speeds from 20 – 200 mm per second, porosity ranges from 80 up to 3000 C.U., perforation lines detection by 0.1 mm, nano micro holes sizes from 0.5 up to 200 µm diameter and up to 250 holes/cm2 to determine all data in real time with internal controller units in order of multiple light transmissions and perforation profiles to determine envelope curves as well porosity profiles and integrals simultaneously.
Thus direct feedback into the perforation system makes it possible to compensate any changes in terms of porosity and perforation locations so that each jumbo roll production up to 25,000.00 meters as well single or quadruple bobbin sets can be produced and controlled without intermediate stops and certificated in quantity, quality on their end.
Outlook
The electrostatic ESP nano or micro perforation usually applies within ranges of the refinement of fine paper, packaging webs, bonded fabrics, non woven, filter, bag, force as well special paper webs of most diverse kind especially when additionally treating course materials for achieving special characteristics which for physical or process reasons cannot be achieved by other process technologies.
Our highly modern, industrially approved ESP perforation technology operation which even can be relied on when operated 24/7 can be integrated into existing rewinding course devices or other course devices. Also, they can be used as completely independent perforation devices.
New ranges of applications will be made accessible as new products with special features will be developed.
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MLL-1 – Micro Laser Line Perforation for holes pattern, perforation design, e.g. waves, zigzag lines, line packages, cryptograms, company logos, holograms, anti counterfeiting product indicators
patent pending for process, device and product property DE102004012081
LPM-1 – nano micro laser perforation at wide web material with high power CO2 dual laser beam multiplexers and splitters, patent grant for process and device DE102004001327
ESP electrostatic nano micro perforation machines for cigarette, tipping, filter, packaging, plug-wrap and other paper products, patent grant for process and device DE10328937 of IGBT power switching unit
Optical online OPSS-1 porovision control/scanning system for ESP or LASER perforation machines,
patent pending for process and device DE10251610 -
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IPM – International Perforation Management
High-tech engineering - China – Germany - Thailand
http://www.microperforation.com
http://www.microperforation.com.cn
http://www.deguodaguan.com/ipm/
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http://www.microperforation.com/mll-1-laser-perforation.html
http://www.microperforation.com/lpm-1.html
http://www.microperforation.com/opss-1-optical-online-porosity.html
http://www.microperforation.com/igbt-esp-unit.html
http://www.microperforation.com/online-perforation-cigarette.html
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