Transferring and Laminating Electrostatically-Printed Images

Transcription

1 Transferring and Laminating Electrostatically-Printed Images Instruction Bulletin 4.7 Release T, Effective November 2010 (Replaces S, Sept 10) See Bulletin Change Summary on last page 1. Table of Contents Description Health and Safety Processing Conditions Recommendations Webbing Diagram Pre Heating and Idle Conditions Material Set Up Start the Transfer Process Stopping the Transfer Process Vehicle and Architectural Windows Warranty and Limited Remedy M Related Literature Bulletin Change Summary Description This procedure is for transferring electrostatically printed images to selected 3M graphic films (referred to also as receptor films in electrostatic imaging) using a GBC/Pro Tech ORCA III Laminator. It also discusses the special laminating procedures required for making graphics for second surface store and architectural windows. A. PTFE-Coated Roller Option A PTFE coated (polytetrafluoroethylene) replacement roll is available for your ORCA III laminator and is also installed on the ORCA III T. This hard coating provides longer life and eliminates the delamination associated with silicone coated rolls. It also reduces the required temperature for image transfer. Encapsulation is not recommended or warranted by 3M when the PTFE roller is installed. Such use requires the graphics manufacturer to test and approve and accept responsibility for the results.! CAUTION The insulation on the laminator's heated steel roll is reduced when you replace the thick silicone cover with a thin PTFE coating. Even brief contact with the heated roll may cause skin burns. To reduce the risk of a burn, keep all body parts a safe distance from the heated roll or wear appropriate protective clothing. B. Overview of Lamination Process In this procedure, several processes occur almost simultaneously: The heated upper main roll softens the surface of the base film so that it can accept the toned image. The pressure of the upper and lower main rolls causes the toner to transfer to the base film. Cooling air is directed between two chrome chill rolls that contact the hot surface of the transfer media and imaged film after passing through the hot nip area. The cooled transfer media is stripped away from the imaged base film. An overlaminate, if used, is applied as the imaged film passes into the nip of the pull rolls, while another core pulls off and takes up the overlaminate's liner. Note: Refer to the individual film's Product Bulletin for the recommended overlaminates. No heat is used in applying most overlaminates. See page 6 for how to order.

2 3. Health and Safety! CAUTION When handling any chemical products, read the manufacturers' container labels and the Material Safety Data Sheets (MSDS) for important health, safety and environmental information. To obtain MSDS sheets for 3M products go to 3M.com/MSDS, or by mail or in case of an emergency, call or When using any equipment, always follow the manufacturers' instructions for safe operation. 4. Processing Conditions Recommendations Important Note! C. Laminator Settings when Using Trident Transfer Paper Please read all instructions in this bulletin and the manual provided by the laminator manufacturer before processing your graphic. The following table includes all base films approved for use with electrostatic imaging using 3M Trident Transfer Media. The list is subject to change without notification. The laminator settings were determined in laboratory tests and may not be the optimal conditions for your shop, laminator or graphics. Graphics manufacturers are responsible for testing, adjusting and approving adhesion and appearance for each film or banner material used. Temperature Heated Film/ Silicon Top PTFE Top Roll Transfer Material Roll Roll Lower Roll 1 Pressure Speed Most Films 290 F 240 F 120 F 95 psi 2.0 to 8.0 fpm F 240 F 120 F 50 psi 2.0 to 8.0 fpm F 240 F 120 F 95 psi 1.5 to 4.0 fpm 3545C 270 F 240 F 120 F 95 psi 2.5 to 4.0 fpm 1 GBC/Pro Tech typically recommends that the bottom roll only needs to be at room temperature at the start of a run. However, the bottom roll will eventually heat up to about 120 F just by heat transfer from the top roll. That means that amount of heat used in the transfer from the beginning to the end of the run would be different. To maintain even transfer heat throughout the run, 3M recommends heating the bottom roll before you begin. 5. Webbing Diagram Supply Roll (overlaminate) Transfer Paper Take up Core Chill Roll (do not use the roll shown in red Liner Take up Core (overlaminate) Upper Heated Main Roll 3M Trident Transfer Paper Hot Top Fan Tube Top Pull Roll Bottom Pull Roll Alternate Webbing when using Outfeed Trim Infeed Cutter (optional) Lower Main Roll Idler Roll Cold Bottom Fan Tube Outfeed Trim Supply Roll (transfer media) Optional Liner Take up Core (transfer media) Finished Graphic Take up Core Supply roll (base film) Instruction Bulletin 4.7-2

3 6. Pre Heating and Idle Conditions 1. Turn on the main power and the upper and lower main roller heating elements. 2. Adjust both sides of the top heated roll shim by turning the shim adjuster UP until it stops at its upper most distance. 3. Adjust both sides of the pull roll shims to Refer to Processing Conditions Summary, page 2, and adjust the set points of the upper and lower heated roll temperature as indicated for the base film you are using. To prevent roll overheating, do not block the heat sensor that measures roll temperature. 5. Adjust the heated main roll pressure to 20 psi. The reduced pressure (20 psi) will extend the life of the roll. 6. Adjust the pull roll pressure to 50 psi. 7. Adjust the pull roll clutch pressure to 50 psi. 8. Turn on the pull roll clutch. 9. Turn off the cooling fans. 10. Lower the upper heated main roll and start the forward motion of the laminator. 11. When the desired operating temperatures are attained, raise the upper heated main roll and stop the forward motion of the laminator. 7. Material Set Up 1. Pull up the shaft lock pin and swing out the supply roll shafts for the base film, the transfer media, and the overlaminate (if used). 2. Remove the core chuck and then slide the materials onto the appropriate shafts. Refer to the Webbing Diagram and note the direction that the material unwinds. 3. Remove all tension from the adjustable core chucks by turning the knurled side of the chuck counterclockwise (when viewed from the outside) until it stops. 4. Reinstall the core chucks, but do not tighten. Swing the shafts back in place and reinstall the shaft lock pin. 5. The rolls of media and film must be aligned by measuring from the frame to the edge of the web. Film and media rolls are usually centered on the machine. Therefore, a 54 inch wide roll should be 7.5 inches from the side frame. For uniform and wrinkle free wind up, the web from the supply roll to the take up core must be an equal distance from the frame. To accomplish this measure the webs at both ends. If needed, adjust the position the base film relative to the images on the transfer media. - If the transfer media is wider than the base film and the images are printed center justified, center the base film on the transfer media. - If the images are printed justified to one side, align that side of the transfer media with the edge of the base film. D. Thread the Base Film 1. Thread the base film into the laminator following the Webbing Diagram on page 2. d. To protect your hands from the heat of the main rolls, pull up 2 to 3 feet of excess film, fold it over on itself, place your hands between the folded film and tuck the fold into the nip area. Go to the other side of the laminator and pull through the folded film. Continue threading the film. e. Most base films can be wound onto the bottom take up core on the output side of laminator with the following exceptions. Measure to make sure the proper distance from the edge of the web to the side frame is maintained from the supply roll to the tape up roll. Then tape the media to the take up core with 3M masking tape. Instruction Bulletin 4.7-3

4 E. Exceptions These films become difficult to manipulate when removing from the small finished graphic take up core. Rather than using the take up core, immediately remove the graphic from the laminator after image transfer to the base film, and lay the film flat on a work table. Any base film to which 3M Scotchcal High Gloss Graffiti-Resistant Overlaminate 8912 is being applied. Any 3M film designed for graphics for floors to which 3M Scotchcal Luster Overlaminate 3645 is being applied. Any 3M Sidewalk Sign to which 3M Scotchcal Matte Overlaminate 3647 is being applied. F. Thread the Transfer Media 1. Thread the transfer media into the laminator following the Webbing Diagram. a. To protect your hands from the heat of the main rolls when guiding the film into the nip area: pull up 2 to 3 feet of excess media, fold it over on itself, and tuck it into nip area. Go to the other side of the laminator and pull through the folded media. Continue threading the media. b. Apply tension 2 to 3 turns to the adjustable core chuck for the transfer media and evenly tension the media onto the take up core. Make sure no wrinkles are formed in the media. c. Measure to be sure the edge of the web is the same distance to the side frame at both the unwind and wind positions. Then tape the media to the take up core with 3M masking tape. 2. If the transfer media is the same width as the base film, proceed to step If transfer media is wider than the base film: a. Measure from both edges of the base film to the laminator frame. b. Adjust the infeed cutters to trim the transfer media at those locations. Refer to the Webbing Diagram on page 2. The transfer media can be 1/8 to 1/4 inch wider than the base film on each side. If the transfer media more than 1/4 inch wider may result in wrinkles. The transfer media cannot be narrower than the base film on either side. Exposing the base film to the heated main roll creates defects in finished graphics. c. Advance the transfer media 2 inches by manually turning the take up core. It may be necessary to loosen the tension on the core chuck. d. Manually cut the transfer media from the trim line out to each edge of the media. e. Advance the media an additional 4 to 6 inches until the trimmed media is under the heated nip area. Allow the waste portion to fall free onto the floor or attach it to the transfer media take up core with masking tape. f. If tension was released in Step 9.c., re apply tension 2 to 3 turns to the adjustable core chuck for the transfer media. G. Thread the Overlaminate 1. Thread the overlaminate (if used) onto the laminator. a. Refer to the Webbing Diagram on page 2. b. Tape the liner to its take up core with 3M Polyester Silicone Adhesive Tape c. Advance the film to separate it from the liner by turning the liner take up core until enough film is exposed to wrap around the backside of the top pull roll. d. Apply tension 1 to 2 turns to the core chuck for the overlaminate and evenly tension the base film around the back of the top pull roll until there are no wrinkles. Instruction Bulletin 4.7-4

5 2. Rotate forward and hold the upper pull roll and overlaminate while lowering the roll. Allow the overlaminate to advance off the supply roll as the top pull roll drops. This forces the adhesive side of the overlaminate into contact with the base film. Roll the excess exposed liner onto the liner take up roll. Remove all tension from the supply roll core chuck. 3. Turn on the cooling fans and adjust the cooling tubes as follows: a. Adjust the slots in the top tube so they face straight down. b. Adjust the slots in lower tube so they face straight up and blow onto the graphic. 8. Start the Transfer Process 1. Refer to the Processing Conditions Summary, page 1, and adjust the heated roll pressure. 2. Adjust the speed control to the 9 o'clock position (approximately 2.0 fpm). 3. Option 1: Simultaneously, turn on the forward motion of the laminator and lower the upper heated roll. This starts the actual transfer process. Option 2: a. Start the forward motion to put tension on the film, transfer media and overlaminate. b. Stop the forward motion. c. Lower the top heated roll. d. Restart the forward motion to start the transfer process. 9. Stopping the Transfer Process 4. Refer to Processing Conditions Summary and adjust the transfer speed. 5. Monitor the tension of the overlaminate. The overlaminate should be dropping off of the liner near the bottom of the liner take up core. See the webbing diagram. 6. Increase the transfer media tension until there are no waves in the media as it enters the heated nip area. Then reduce the tension as far as possible while still maintaining a smooth, wave free surface. - If waves appear, increase the tension. - If hard creases appear, decrease tension. 7. Monitor the tension of the base film. Do NOT apply tension to the supply roll core chuck unless the base film is bunching up in front of heated nip area. Even in that case, apply only enough tension to allow the film to lay flat against the lower main roll. 8. To determine the correct transfer speed: a. If you are getting 100% transfer of the toned image to the base film, increase the transfer speed by 0.5 fpm and monitor for complete transfer for one full minute. b. Continue to increase the transfer speed in 0.5 fpm increments, waiting one minute between increases, until less than 100% transfer is observed. c. Decrease the speed to the last setting that achieved complete transfer. 9. The temperature of the heated main rolls drops at the beginning of transfer process and slowly rises up to the set points. As the temperature increases, the transfer speed may also be increased. 10. Continue to monitor the tension of the overlaminate supply roll. Decrease the core chuck tension of the roll as the diameter decreases to maintain even tension.! CAUTION Use care to avoid cutting the heated rolls and pull rolls when cutting the media. Cuts in these rolls cannot be repaired. Instruction Bulletin 4.7-5

6 1. Raise the top heated main roll when the last image has passed through the heated nip. Do NOT allow the heated roll to come in contact with base film that is not covered by transfer media. The film may become deformed, melt onto the heated main roll and/or separate the liner from the film. 2. Stop the laminator when the last graphic has passed through the pull rolls using the following technique. Raise the hot roll when the last image has passed through the heated nip. Then allow the last graphic to pass the pull rolls before stopping the laminator. This technique helps ensure that the transfer media breaks free from the receptor film, helps prevent bubbles and allows the operator to manipulate the transfer and receptor webs independently. 3. Remove all tension on the transfer media core clutch. 4. Have you completed all transfers from this roll of transfer media? YES a. Cut the transfer media just inside of the steel idler roll. b. Quickly wind the remaining transfer media onto the take up core and tape it in place. This eliminates the chance of the used transfer paper getting stuck to the adhesive of the overlaminate. c. Back wind the transfer media supply roll and remove it from the laminator. NO a. Hand advance the printed media to the next image on the roll. b. Reset the media supply roll tension. c. Lower the main heated roll and continue transferring. 5. If all transferring is finished, raise the top pull roll. 6. Have you completed using this overlaminate? YES a. Cut the overlaminate at the point of contact with the base film. b. Rewind the overlaminate back onto the supply roll, cut the liner by the roll and tape in place. NO Leave the overlaminate in this position 7. Have you completed using this receptor film? YES a. Cut the non-transferred base film next to the outer chrome chill roll. b. Wind the final graphic onto the take up core or lay it flat on a table. c. Rewind the base film onto the supply roll and tape it in place. NO a. Pull the base film out past the pull rolls. b. Repeat the start up procedures to continue the transfer process. 8. If the laminator will be idle for longer than 30 minutes: a. Be sure the image transfer media, film and overlaminate have been cut, rewound and taped in place. b. Turn off the cooling fans. c. Reduce the heated roll pressure to 20 psi. d. Lower the top heated roll. e. Start the forward motion of the laminator, running at 2.0 fpm until the next transfer operation. 9. If the laminator will be idle for four hours or longer, shut off all power to the laminator to conserve energy. Instruction Bulletin 4.7-6

7 10. Vehicle and Architectural Windows These procedures are for electrostatically imaging window graphics using the following products, which are applied on the first surface (the side from which you view the graphic). For specific fleet application requirements, refer to the film's Product Bulletin. Use overlaminate 8914 when an optically clear view is required. If protection for inks or toners is all that is required, you can use a screen print clear. 3M Scotchcal Perforated Window Graphic Film 8671 ES 3M Scotchcal Perforated Window Graphic Film ES 3M Scotchcal Optically Clear Overlaminate M Screen Print Clear 8920 A. Image Transfer 1. Print the image on Trident transfer paper. 2. Using the GBC/Pro Tech ORCA III, transfer the image to the white side of the window graphic film. 3. Follow the processing recommendations starting on page 2 and taking into consideration the following points. a. Be sure nothing obstructs the film as it exits the hot rollers. Perforated films are not as stiff as other graphic films, so obstructing the outfeed may cause the film to buckle at the hot nip and separate from the liner. b. Takeup cores. For this step, you can wind the film onto the take up core on the laminator, or you can wind in onto a standard film core. However, since the standard film cores are shorter, you need to add core extensions. The following diagram provides guidelines. c. As you remove the transfer media from the film, notice that half of the image still remains on the media. The image that is on the film appears lighter than the same image transferred to non punched film. Increasing the saturation of the colors using your design station software may compensate for some of the image loss. Dimension Core Length Extensions (requires 2) A 54 inch 6.25 inch B 49 inch 8.75 inch C 36 inch inch 5 ± 1/4 A, B or C 3 OD Tubing 3 ID Tubing B. Applying an Overlaminate (1) Overlaminate 8914 Starting Settings to Reduce Curl Top brake: 20 psi (on laminator Model 9540) Laminator roll pressure: 20 to 30 psi Minimum back tension (2) Screen Print Clear 8920 See Instruction Bulletin C. Application Tapes Do NOT use an application tape (premasking or prespacing) on film that has been laminated with overlaminate The adhesive of the application tape can pull the overlaminate or image off the graphic. 11. Warranty and Limited Remedy The information contained and techniques described herein are believed to be reliable, but 3M makes no warranties, express or implied, including but not limited to any implied warranty of merchantability or fitness for a particular purpose. 3M shall not be liable for any loss or damages, whether direct, indirect, special, incidental or consequential, in any way related to the techniques or information described herein. Instruction Bulletin 4.7-7

8 12. 3M Related Literature Before starting any job, be sure you have the most current Product and Instruction Bulletins. The information in 3M Product and Instruction Bulletins is subject to change. Current Bulletins are available at 3Mgraphics.com. The techniques described in these Bulletins are required when applying a 3M warranted graphic, but are also practical recommendations when using promotional materials for non-warranted graphics. Additional Bulletins may be needed as indicated in the 3M Related Literature section of other 3M components you use. Bulletin types: PB = Product Bulletin; PB-IB = Product & Instruction Bulletin; IB = Instruction Bulletin Subject Type Bulletin No. Base Films and Substrates Please visit our website to identify and select the additional Product and Instruction Bulletins you need for a successful application. 3M Graphic Protection Products overview of all graphic protection products PB GP-1 and specific information on most overlaminates 3M Screen Print Clear 8920 ES PB-IB M, the 3M logo, Comply, Controltac, MCS, and Scotchcal are trademarks of 3M. Scotchprint is a registered trademark of 3M. ORCA III is a trademark of GBC/Pro Tech 13. Bulletin Change Summary General format changes. Commercial Graphics Division 3M Center, Building E-04 PO Box St. Paul, MN USA General Info Technical Info Fax M Canada P.O. Box 5757 London, Ontario Canada N6A 4T Fax M México, S.A. de C.V Av. Santa Fe No. 55 Col. Santa Fe, Del. Alvaro Obregón México, D.F Fax M Puerto Rico, Inc. Puerto Rico Industrial Park 350 Chardon Avenue, Suite 1100 San Juan PR Fax M All rights reserved. Instruction Bulletin 4.7-8