電暈處理機的發(fā)展歷史.docx

電暈處理機的發(fā)展歷史標簽： 軟包裝;電暈處理機;陶瓷電極;氣隙;表面張力分類： 軟包裝技術(shù) History of Development電暈處理技術(shù)的發(fā)展歷史The configuration of the electrode has taken many forms. One of the earliest forms was a simple wire stretched parallel to the ground roll which was covered by a dielectric such as polyester wrapping. The wire electrode (see Figure 10) accomplished its purpose, but provided such a narrow corona that the dwell time, the time which the substrate actually spent in the presence of corona, was exceedingly short. In addition, the power level that could be applied was extremely limited by the cross section capacity of the wire and its ability to dissipate heat generated during treatment. Ozone, which is always produced in the corona-filled air gap, had to be removed from the work environment. （電暈處理機的）電極的構(gòu)造有多種形式。其中最早期的一種形式是一根被張緊的電線與底輥相平行配置的形式，底輥上覆蓋著絕緣物，例如聚酯。這種線型電極（參見圖10）能夠?qū)崿F(xiàn)電暈處理的目的，但是它所提供的電火花過于狹窄，以至于處理時間-被處理的的基材在電火花中停留的時間-非常短暫。另外，由于線型電極的截面容量（cross section capacity）較小，驅(qū)散在電暈處理過程中所產(chǎn)生的熱量的能力較差，所以，該種電極所能輸出的功率級是非常有限的。而且，必須將充斥在生產(chǎn)環(huán)境中的臭氧不斷地排除出去，這些臭氧是在線型電極與底輥間的氣隙間的電火花中不斷地生成的。Another early form of electrode was a threaded rod which provided more dwell time, but because of the unevenness of the electrode surface, it had a tendency to create uneven treatment across the transverse of the substrate. Corona has a tendency to be more intensive at sharp points in the electrode (see Figure 11), causing higher treatment level where the threaded portion is closer to the substrate. 另一個早期的電極型式是螺線桿（threaded rod），它能夠提供較長的處理時間（dwell time），但是，由于該電極的表面是不光滑的，所以，它有可能在基材的橫截面上造成不均勻的處理效果。由于電火花往往集中在電極的尖端處（參見圖11），因此，會在螺線桿與基材更接近的部位產(chǎn)生較高的處理水平（程度）。Straight metal bar electrodes were also used, and are still being used today. The bar produces even treatment across the substrate but requires a new electrode to be cut to length to match the web width each time the web is changed. This is inconvenient for the operator and requires a storage system for various lengths of electrode (see Figure 12). 直線型金屬棒電極（Straight metal bar electrodes）也被使用過，而且今天仍然在應(yīng)用中。該電極能夠在基材的橫斷面上產(chǎn)生均勻的處理效果，但是，當基材的寬度發(fā)生變化時，就需要更換一根新的與基材寬度相匹配的電極。這對于操作者來說是不方便的，而且還需要事先儲備不同長度的多個電極（參見圖12）。In order to overcome the need to cut electrodes to length, bar electrodes were cut in segments and mounted on a rod so that when web width changed, segments could be moved away from the ground roll, thus matching the electrode length to the web width (see Figure 13). Many such electrodes are being used today. This configuration of electrodes has several advantages and disadvantages. 為了解決這一問題，直線型的金屬棒電極被切割成許多小段，然后安裝在一根金屬桿上，這樣一來，當基材的寬度變化時，其中的一些電極可以被從底輥表面移除，從而使電極的寬度與基材寬度相匹配（參見圖13）。這種電極今天仍在被廣泛使用。這種形式的電極有一些優(yōu)點，也有一些缺點。When the segmented electrode was mounted directly above the ground roll, the segments would swing out of the way when a wrinkle or splice greater than the air gap would pass over the ground roll and drop back into place when the wrinkle or splice had passed. Another advantage of the segmented electrode is the ability to raise center segments and allow strip treating. In earlier electrodes, a thick splice striking the electrode could cause it to be damaged. A corresponding disadvantage is that ozone produced in the corona soon formed aluminum oxide deposits between the segments, thus causing them to remain in the nontreat position. This problem can be overcome to some extent by hardcoating or anodizing the segments. A further improvement is the use of stainless steel as the electrode material. This has virtually eliminated sticking of segments or warpage of the electrode. 當這種分段電極（segmented electrode）安裝在底輥上后，如果基材上有大于氣隙的皺褶或接頭通過底輥時，分段電極就會擺離（swing out）底輥，而當皺褶或接頭已經(jīng)通過底輥后，分段電極還會返回其原始位置。分段電極的另一個優(yōu)點是可以將中間的電極升起，以便進行帶狀處理。在早期的分段電極中，過厚的接頭有可能會造成電極的損壞。相應(yīng)的缺點是：在電火花中產(chǎn)生的臭氧會生成氧化鋁并沉積在分段電極間，導(dǎo)致分段電極不能返回其初始位置。這個問題可通過對分段電極進行表面硬化處理或陽極化處理得到某種程度的緩解。進一步的解決方法是使用不銹鋼作為電極的加工材料。該方法事實上消除了分段電極間的粘連或電極的熱變形的問題。A final drawback to this configuration is the possibility of uneven treatment across the web. 這種電極型式的最大缺點是在基材的橫斷面上的處理程度的不均勻。A substrate having treatment that is not uniform across the web may cause bonding or heat-seal problems in printing, extrusion coating, coating, and laminating. Uneven treatment has been greatly alleviated by bias cutting of segments to prevent strip treating between segments. 已經(jīng)過電暈處理、但在橫斷面上處理程度不均勻的基材可能會在印刷、擠出涂布、表面涂層處理和復(fù)合加工中導(dǎo)致附著力、粘接強度和熱封問題。通過對分段電極進行斜切處理（bias cutting）以防止電極間的帶狀處理，該問題已被極大地緩解了。The covered roll system using a dielectric covered roll with either a bar or segmented electrode alsopresented a size problem. In order to properly treat a given web width and dissipate heat generated during the treating process, the coated roll diameter must increase directly with the total applied power. Heat buildup on coated rolls is very destructive and can only be mitigated by increasing the roll diameter to allow a period of cooling between cyclic positioning under the electrode. In addition, to provide ozone removal and operator safety, the station as a whole must also increase in size as the roll diameter increases. Figure 14 indicates roll diameter requirements as a function of applied power (kW). 包覆輥系統(tǒng)（the covered roll system, 絕緣體包覆的底輥，不管配備的是棒狀電極還是分段電極）都存在著尺寸問題。為了適當?shù)靥幚斫o定寬度的基材，并驅(qū)散在處理過程中產(chǎn)生的熱量，隨著施加的能量的提高，包覆輥的直徑必須增大。在包覆輥上的熱量具有很大的破壞性，只能通過增加包覆輥的直徑使之在周期性的處理過程中有一個冷卻階段才能得以緩解。另外，為了移除臭氧和操作者的安全，伴隨著底輥直徑的增加，電暈處理機的整體尺寸也需要增加。圖14標示了包覆輥直徑與電暈處理機功率（kW）的關(guān)系。 Another method which has been attempted without much success is to use several sets of segmented electrodes which are staggered so that each row of segments covers the air gap from the previous row (see Figure 15). This solution has not proven reliable. Recent tests indicate that significant uneven treatment still occurs. 另一個曾經(jīng)被應(yīng)用過但不太成功的方法是使用交錯排列的多套分段電極（參見圖15）。這一方案的可靠性沒有得到證實。近期的試驗顯示依然存在著值得注意的處理不均勻的狀態(tài)。 Two early electrodes which were attempted involved a glass tube with a metal rod insert and a glass tube filled with steel wool (see Figure 16). This was an entirely new concept because, for the first time, the dielectric cover was removed from the ground roll and placed on the electrode. This early bare-roll configuration promised a great many advantages but was soon abandoned because expansion of the metal rod, due to a rising temperature, broke the glass tube. Even when the electrode was rotated to spread the corona over a 360 degree revolution, neither overheating nor breakage was prevented. 兩個較早的不成功的電極系統(tǒng)，包括一個插入了金屬棒的玻璃管和一個充填了鋼絲棉的玻璃管（參見圖16）。這在當時是一個全新的概念，因為它第一次從底輥上取消了絕緣覆蓋物，并直接包覆在了電極上。這一較早的光輥（bare-roll）系統(tǒng)顯示了許多的優(yōu)點，但很快就被放棄了，因為隨著溫度的升高，金屬棒膨脹，玻璃管就被脹破了！盡管曾將該玻璃電極旋轉(zhuǎn)以分散電火花，但既不能防止過熱也不能阻止玻璃管的破裂。Another serious consideration should be mentioned here. None of the metal electrodecovered-roll configurations work when treating conductive substrates such as foils or metallized film, and a very complex form of electrode was required (see Figure 17). 這里應(yīng)該強調(diào)一下另一個重要的方法。當需要處理導(dǎo)電性的基材，例如鋁箔或鍍鋁薄膜，時，沒有一個金屬電極包覆輥系統(tǒng)是可用的。此時，需要一個非常復(fù)雜的電極形式（參見圖17）。This early bare-roll system consisted of a metal ground roll and a series of dielectric covered electroderolls that were driven. This is a very expensive, cumbersome method of treating conductive substrates， but it was the only method available 這種早期的光輥系統(tǒng)（bare-roll system）由一個金屬底輥和一組可主動旋轉(zhuǎn)的絕緣體覆蓋電極輥所組成。這是一個非常昂貴、非常復(fù)雜的處理導(dǎo)電性基材的方法，但在當時又是唯一可行的方法。In 1980, a new configuration of electrode capable of operating on a bare roll was developed which surmounted the basic problems that were experienced up to that point. This electrode achieved the following operational goals (also see Figure 18): 1980年，一個新的能夠在光輥上操作的電極系統(tǒng)誕生了，它解決了在此之前所遇到的眾多基礎(chǔ)問題。這個電極達到了下列的操作目標（參見圖18）。1. Even corona treatment across the transverse of the substrate. 在基材的橫斷面上的均勻的電暈處理效果。2. Eliminating the need to adjust the electrode to web width.去除了調(diào)整電極長度以適應(yīng)基材寬度的需求。3. Eliminating the dielectric roll covering which required frequent replacement and entails an inventory of spare rolls as well as considerable production loss during replacement of a burned-out roll.取消了絕緣輥包覆物，該包覆物需要不時地更換、需要有備件庫存、以及在更新過程中難以估量的生產(chǎn)損失。4. Allow corona treatment of both conductive and nonconductive webs using a simple system without driven treater rolls. Further, even perforated webs can be treated with this type of electrode.可以使用這個沒有主動處理輥的簡單系統(tǒng)處理導(dǎo)電性基材和絕緣性基材。甚至網(wǎng)孔狀的基材也可以在這種類型的電極上進行處理。5. Allow splices to flow through the corona treating station without striking the electrode despite the close position of the electrode relative to the treater roll.In addition to achieving these operational goals, this new electrode configuration also eliminated the need for a closed cabinet to remove ozone. Conventional corona treating systems require a closed cabinet not only to remove ozone in the operator area, but to prevent electrical shock to operators who are required to work in close proximity of the corona treating station. This recently patented electrode assembly meets all the operational and safety requirements of extruders and converters (see Figure 19). 除了達到這些操作目標之外，這種新的電極系統(tǒng)也取消了用以去除臭氧的封閉式機殼。傳統(tǒng)的電暈處理系統(tǒng)需要一個封閉式的機殼，不僅是為了去除臭氧，也是為了防止對操作者發(fā)生電擊，因為操作者有時需要在接近電暈處理機的位置上進行工作。Substrates can even be selectively treated leaving specific areas untreated as in the previously mentioned heat-seal applications (see Figure 20). The concept that made this electrode possible was the use of a rectangular ceramic tube filled with irregularly shaped aluminum alloy granules. 基材甚至可以被有選擇性地進行處理，以在基材上留下特定的未處理區(qū)域，就象前面論述過的熱封應(yīng)用中（參見圖20）。使得這種電極成為可能的理念是：在方形的陶瓷管中填充入形態(tài)不規(guī)則的鋁合金顆粒。When these granules heat up, they do not break the ceramic tube since there is sufficient room for their expansion. 當這些鋁合金顆粒物被加熱后，它們不會使陶瓷管破裂，因為在管內(nèi)有足夠空間供其膨脹。This electrode is accepted as the latest state-of-the-art in Europe as well as the United States. 這種電極在歐美被公認為是最完美的。Hundreds of production lines use this type of system, which proved its ability to treat to high levels while providing long-term reliability. 成百上千的生產(chǎn)線使用了這一系統(tǒng)，它證實了其高水平的處理能力以及長期運行的可靠性。Why ceramic? It is a material which combines the attributes of dielectric strength with a high electrical power per square inch to enable high treatment levels. A ceramic was developed which allowed twice as much power per square inch to be applied to each electrode. The ceramic electrode achieved this higher treatment level because of its higher dielectric constant and lower electrical reactance. These factors allow the ceramic electrode to provide a higher treatment level for a given applied voltage. Furthermore, since ceramic is less sensitive to high operating temperatures, higher power levels can be applied and maintained to provide consistently higher levels of treatment per electrode. 為什么是陶瓷？因為它是這樣一種材料：既有一定的絕緣強度的屬性，又有較高的單位面積電功率輸出能力，使達到較高的電暈處理水平在技術(shù)上成為可能。陶瓷材料現(xiàn)已發(fā)展到這樣的水平：使每支陶瓷電極每平方英寸可以輸出的電能兩倍于以前的電極材料。這種陶瓷材料能夠達到這樣高的處理水平是因為它具有較高的絕緣常數(shù)和較低的電阻。這些因素使得陶瓷電極能夠在給定的電壓條件下達到較高的處理水平。與此同時，陶瓷對高的操作溫度較不敏感，因此，較高的功率水平才能夠被輸出，并且保持每支電極常態(tài)化的較高的處理水平。Any electrode, be it metal or ceramic, has a limit of effective output based upon the total bar area of the electrode. In the past, bar area of a metal electrode was increased by cutting the face closest to the ground roll in a concentric curve to follow the roll face (see Figure 21).任何一種電極，不管是金屬的或陶瓷的，基于它的總的電極表面積，都會有一個有效輸出功率的限值。以前，增加金屬電極棒的面積的方法是將電極朝向底輥的面加工成與底輥相同的同心圓（參見圖21）。As more and more power is applied to a given electrode, an ultimate limit is reached at which further power applied is wasted. Therefore, as power density requirements increased, corona treating systems required additional electrodes. The power capacity of the ceramic electrode reduces the number of electrodes by one-half, thus producing a smaller and less expensive station (see Figure 22). 隨著給每一支電極施加的電能量的不斷增加，輸出功率的極限就達到了，此時再想增加輸出電能的努力都是無用的。因此，隨著功率密度需求的增加，電暈處理系統(tǒng)就需要增加電極數(shù)量。新的陶瓷電極功率輸出能力將電極的數(shù)量減少了一半，這樣就能生產(chǎn)出體積較小的和較便宜的電暈處理機了（參見圖22）。Recent advances in dielectric roll coverings and power supply design have made hybrid systems possible that greatly enhance the level of treatment on difficult to treat substrates. 近期在絕緣輥包覆材料和電源設(shè)計方面的進步使得隨之而來的綜合性電暈處理系統(tǒng)能夠極大地強化在難處理基材上的處理水平。Ceramic electrodes with tightly controlled watt density and frequency can be operated over a treater roll coated with a special ceramic (see Figure 23). The result is an improved level of treatment on difficult to treat substrates such as cast film, polypropylene with high levels of slip additives, etc.具有嚴格控制的（tightly controlled）功率密度和頻率的陶瓷電極可以應(yīng)用在有特殊陶瓷涂層的處理底輥上（參見圖23）。其結(jié)果是在諸如流涎膜、高爽滑劑含量的聚乙烯膜等難處理基材上實現(xiàn)了較好的處理水平。In bare-roll and “H” system treater stations, ceramic electrodes are attached in the assembly to allow removal and replacement in less than 10 minutes. This changeover time is critical when production loss and cost due to downtime can be measured in hundreds or thousands of dollars per hour. 在光輥（bare-roll）和如圖23所示的“H”系統(tǒng)中，陶瓷電極的取出與更換可在10分鐘內(nèi)完成。在停機損失或費用以每小時數(shù)百或數(shù)千美元計算的企業(yè)中，這么短的更換周期具有決定性的意義。Corona treating electrodes have come a long way from wire, to segmented metal, to specially formulated ceramic. Each time advancements are made, it would be wise to review what constitutes the ideal electrode. Some characteristics are described here: 電暈處理電極已經(jīng)走過了漫長的路程，經(jīng)歷了線型電極、分段電極、直到特殊的陶瓷電極。每一次取得進步時，回顧一下什么才是理想的電極是一件很有意義的事情。以下陳述了一些特征。1. The electrode must provide a controlled level of even treatment across the web. 電暈處理電極必須能提供可控的在基材橫斷面上均勻處理的能力。2. The electrode should provide treatment to both conductive or nonconductive webs.Figure 22. Ceramic Electrode. 電暈處理電極應(yīng)能夠處理導(dǎo)電性和絕緣性的基材（圖22，陶瓷電極）。3. The