fusing machines

7/30/2019 Fusing Machines

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FUSING MACHINES

BY-

SHEIKH KASHIF FAIZ

MAMSHI OSHIN

VASWEE DUBEY

S.P.M.E.


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FUSE-ON INTERLININGAREFABRICATIONCOATEDWITHSOMEFORMOFRESINOR

ADHESIVETHATSERVESASABONDING

AGENTTOHOLDTHEINTERLININGTOTHE

SHELLFABRIC

S.P.M.E.


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REQUIREMENTSFOR FUSING

BaseCloth

Adhesives

Coating System Interlining


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Good fusible interlines must have:

Good bond strength

Good peel bond after wash

Controlled differential shrinkage

Active shrinkage and elongation through wash

and dry process

Does not get effected due to steaming

Can withstand overheat and pressure

S.P.M.E.


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PHYSICAL COMPONENTSOF

FUSING

Temperature:

range from 130 to 180oC (250oF to 355oF)

Pressure : 30psi-45psi

Time :

12 to 20 seconds

Cooling under pressure

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WHATIS FUSING TEMPERATURE ?

Fusing in fact is lamination of two ore more textile

surfaces by using thermoplastic resins. Therefore

temperature is the most important factor for the

application of fusing. In the day-to-day practice

there are generally two kind of temperaturementioned:

1. the temperature suggestion of the

interlining supplier,

2. the temperature setting or reading on the

fusing machine.

S.P.M.E.


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FUSINGPROCEDURE

Always ensure the fusing machine is properly heated upbefore starting bulk production every day or shift. Always testusing same bulk panels.

Interlining must be at least 2 mm shorter all around thefabric panel to be fused.

Never cut interlining larger than the fabric. This way, gluewill contaminate the conveyor belt and fabric.

Use carrier sheets while loading the fusing panels toensure that the interning panel is not moved while loading.

Fusing speed, roller pressure and temperature must becorrect as specified by supplier otherwise any incorrectstandard will result in defective poor fusing quality.

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Never use sandwich or multi layer fusing to save time. This willresult in poor fusing quality.

Machine head changed must be checked for uniformtemperature otherwise poor quality fusing will result.

If fusing by hand iron then iron must be placed firmly withweight and must not be slide across the panel.

Proper maintenance of machine is done on regular basis. Never use steam iron for using panels.

Do not blow cold air around fusing machine but rather use awell-ventilated area for good working atmosphere.

Always do testing by coordinated matching of fabric andinterlining in warp and weft direction

Interning must always be fused with interning on top of thefabric and not upside down.

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S.P.M.E.


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FUSINGTECHNIQUE

Single Fusing Fusible positioned on the top of the Cloth

Reverse Fusing Cloth is Positioned on the top of Fusible

Sandwich Fusing Fusing 2 components in 1 operation

Cloth on the outside, 2 fusible in the middle

Double Fusing

Fusing 2 fusible positioned one on the top of other, to the top cloth in 1operation

Top Fusing Fusible components are positioned on the top of the cloth and heat I applied

directly to the top cloth

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A FUSINGMACHINEHASDIFFERENTTEMPERATURELEVELS:

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Fusing Equipments

Flat Bed PressContinuous

Fusing Machine

Hand Iron Steam Press

High FrequencyFusing


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FLAT BED PRESS

Padded top and Bottom bucks

Heating Element in 1 or both bucks

Bottom Buck Static, Top buck can be

moved vertically

Option of Single tray and Twin tray systems Low Productivity

The three processes are Loading, Fusingand Cooling.


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CONTINUOUS FUSING PRESS

Use of Conveyor Belt as a mean of transport Synchronized belt speed

Heating plates, cylinder, rollers, and heatingzones are used

Rubber covered steel rollers to apply pressure

Air cooling and water cooling systems

Take off could be done manually or mechanically


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S.P.M.E.


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HIGH FREQUENCY FUSING

Multiple plies are stacked up (up to 70 mmheight) and fused simultaneously

High Productivity

Heat from high frequency energy

No shrinkage or color change

Dielectric heat: plates generate highfrequency field, heat effect is distributeduniformly in length ,width and full heightbetween platen


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HIGH FREQUENCY FUSING

Heating effect is different for differentpolymers

Adhesive is heated up faster than fabric or

interlining Time depend on capacity ofHigh

Frequency unit and weight of load to befusedo

E.g.; 30 Kw unit ; load 5-20 kg : 1-3 min Disadvantage: the press needs to be set for

fusing materials on basis of fibre, content,weight thickness and moisture content


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S.P.M.E.


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HOWTOCHECKTEMPERATUREANDHEATING

SYSTEMOFAFUSINGMACHINE

Most suitable for a temperature test are the well-known papermeasuring tapes.

The measured temperature between the belts (without fusingmaterial) at medium machine speed should be in accordance withthe temperature reading on the thermostat.

In case of a separate digital temperature reading it should, afterheating-up of the machine, indicate exactly the temperaturesetting.

The easiest way to test the glueline temperature is also by usingthe paper tapes.

To test the capacity and the reliability of a heating system one

should prepare a number of swatches of heavier fabric andinterlining with temperature tapes in-between, pass them throughthe machine successively and compare the results: All tapesshould show the same temperature.

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THEHEATINGCAPACITYANDTHEGEOMETRY

OFTHEHEATINGZONES

are decisive for the application of a fusing machine in view ofthe material to be fused:

Lighter material like for shirts, blouses or dresses requiregenerally lower heating capacity or shorter heating zones.

In this case the main heat should come through the face fabricside, in order to have the melting resins flow towards the face fabric.

If primarily heavier fabrics are to be fused, or in case ofsandwich

ormulti-layer fusing, higher heating capacity and a longer heatingzone is needed to make sure that the machine capacity can followthe loading speed of the operators.

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1. Heating Profiles: with specially treated surface and optimumcurvature for best belt contact

2. Heating Mat: intimately laminated to the inside of the profile

for best heat transfer

3. Sensor Position: ideally next to heating mat and belt contactsurface for quick reaction

4. Contact Surface: continuous contact with the belts forcontinuous heat flow

5. Profile Thickness: relatively thin for fast heat transfer to the beltsurfaces

6. Curved Heating Zones: for intensive contact between materialand heating surface by high fusing belt tension

7. Separate Heating Zones for optimum adjustment of thetemperature balance according to fusing method.

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The best heating system does not make sense when

the temperature control system is poorly designed.

Its functions must be fast and precise.

At any time the temperature on the belt surface must

correspond with the reading of the temperature

regulator.

There may not be any temperature swing, regardless of

the degree of loading the machine with material.

A slow reacting control system leads to unacceptable

temperature variations, whereas a fast reacting system

keeps the fusing temperature on a constantly even level

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SPECIFIC PRESSUREAND PRESSURE EVENNESS

Contrary to flat bed presses, it is almost impossible oncontinuous fusing machines, to determine the exact

pressure applied to the material to be fused.

The specific pressure is not only depending on thepressure reading on the pressure dial, but also from a fewadditional factors, such as:

hardness, thickness and surface of the silicone coating,

thickness and hardness of the material to be fused

degree of machine width coverage.

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Therefore when fusing with a machine equipped with aconventional pressure system the pressure adjustment must

be decided after fusing tests with the specific material.

A swatch of a standard part width should be used for findingout the optimum settings, considering the best possible bondstrength, surface and handle results.

Additionally it is advisable to tests the evenness of thepressure over the working width of the fusing machine.

After testing the evenness of temperature one should load themachine over the working width with several samples of the

same material combination and check the bond strength ofall samples.

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FLEXIBILITYBYDIFFERENT PRESSURE

SYSTEMS

S.P.M.E.

Single Pressure

System

* all kind of ordinaryfabrics

* outerwear mainly

* reliable and sturdy

Double Pressure

System "CU"* special treated fabrics

* dress and casual shirts

* flexible pressure range

* for all kind of interlining


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S.P.M.E.

Flexo Pressure System

* for sensitive fabrics

* balancing thick and thin fabric

* soft pressure supply

* for single and sandwich fusing at the same time

* sadwich fusing

* thick and thin shell fabric at the same time*high quality fusing for outerwear


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THE CONVEYOR SYSTEM The conveyor belts are the most delicate design elements of a

continuous fusing machine. Their function, however, is crucial for theperformance of all other elements.

- They must be strong, with high tear and tensile strength.

- The surface must be smooth, to avoid marks or structure transferon delicate fabrics.

- The surface should not allow any resin adherence.- They must withstand temperatures up to 250 Celsius.

- They must be thin for optimum heat transfer.

- They may not change their dimensions when heated up.

- They must have a smooth teflon coating.

- To avoid shifting of material they must have an antistatic

treatment.- To avoid marks they should not have a thick welding joint.

- The belt edges must be sealed, to avoid fraying.

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1. Cover Belt: - endless high tech fabric

- smooth surface

- Teflon coating

2. Tracking Sensor: - for sensible belt tracking control

3. Control Roller: - gentle horizontal movement

- no over stretching of belts

4. Safety Sensor: - for additional safety

- stops machine if belt goes off

5. Belt Tensioning: - for uniform belt tension

- for intensive heat contact

6. Tensioning Roller: - for compensation of belt tension

- for centered belt tracking

7. Transport Belt: - endless high tech fabric

- smooth surface

- Teflon coating

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PROBLEMS FACED IN FUSING MACHINES

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CAPACITY

The capacity depends on material, quantity and variations offabrics and interlinings to be fused. The exact capacity canonly be calculated according to the individual situation of theparticular production.

The individual capacity calculation considers:

- all fabric and interlining parts,

- the fusing method,

- planned or actual production figures,

- daily working time or shift time in minutes,

- the individual efficiency,

- the individual cost per minute.

(- Example stated in the document)

S.P.M.E.


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REFERENCES:

http://www.fusingbelts.com/all_about_fusing/all_abo

ut_fusing_on_fusingbelts.html 11-5-13 (17:50)

http://www.fusingbelts.com/Fusing%20tests/fusing

%20tests.pdf 5-5-13 (12:13)

http://www.indiantextilejournal.com/articles/FAdetail

s.asp?id=3927

5-5-13 (12:20)

S.P.M.E.
http://www.fusingbelts.com/all_about_fusing/all_about_fusing_on_fusingbelts.htmlhttp://www.fusingbelts.com/all_about_fusing/all_about_fusing_on_fusingbelts.htmlhttp://www.fusingbelts.com/Fusing%20tests/fusing%20tests.pdfhttp://www.fusingbelts.com/Fusing%20tests/fusing%20tests.pdfhttp://www.indiantextilejournal.com/articles/FAdetails.asp?id=3927http://www.indiantextilejournal.com/articles/FAdetails.asp?id=3927http://www.indiantextilejournal.com/articles/FAdetails.asp?id=3927http://www.indiantextilejournal.com/articles/FAdetails.asp?id=3927http://www.fusingbelts.com/Fusing%20tests/fusing%20tests.pdfhttp://www.fusingbelts.com/Fusing%20tests/fusing%20tests.pdfhttp://www.fusingbelts.com/all_about_fusing/all_about_fusing_on_fusingbelts.htmlhttp://www.fusingbelts.com/all_about_fusing/all_about_fusing_on_fusingbelts.html


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THANKYOU

S.P.M.E.

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