Roll-to-Roll (R2R) functional film coating covers six major product types: silicone release film, protective film, high barrier film, conductive film, HC hard coat and anti-static coating. It features an extremely wide range of coating weights and coating fluid viscosities. Traditional production lines rely on a mix of peristaltic pumps, diaphragm pumps and screw pumps, leading to complicated spare parts management and inconsistent calibration curves.
JONSN’s three-tier gear pump portfolio (MPG micro series, MRA medium-viscosity series, DP high-viscosity series) adopts a unified positive displacement principle. One single platform supports all six functional films, covering ultra-light coating weights from 0.05 g/m² silicone coating up to 50 μm thick hard coat layers.
▎Coating stripes induced by flow pulsation under ultra-low coating weightSilicone release film and anti-static coating adopt ultra-low coating dosage. At high line speeds, subtle pulsation from conventional pumps creates visible stripes on the substrate, resulting in uneven release force or unstable surface resistance and massive product rejection.
▎Tiny proportion deviation in multi-layer barrier film leads to full roll scrapHigh barrier films for food packaging and OLED encapsulation consist of 5–10 alternating organic/inorganic layers. Minor flow mismatch between layers amplifies defects during subsequent CVD/ALD deposition, scrapping entire 6,000-meter rolls. Synchronization accuracy of parallel pumps and batch repeatability directly determine production yield.
▎Poor material compatibility with complex solvent systems for coating fluidsCoating lines frequently switch between silicone solvents (toluene/xylene), adhesive solvents (ethyl acetate/MEK), aqueous/alcohol conductive polymer dispersions, UV hard coat solutions and water-based anti-static agents. Ordinary pump wetted parts swell, precipitate contaminants or corrode after long-term immersion in aromatic hydrocarbons, ketones, esters and alcohols.
▎Any pump shutdown scraps the full roll of substrate in continuous R2R operationOnce R2R coating lines start, substrates run continuously at 100–600 m/min. Unexpected pump shutdown triggers full roll waste, extra coating head cleaning and time-consuming rethreading. Pumps must deliver ultra-high reliability without unplanned downtime.
Silicone Release Film – MPG Series (40 μL/r)Multi-tooth precision gears reduce pulsation amplitude to 1/5 of standard dual-tooth pumps. Servo closed-loop control limits coating weight CV below 2% at maximum 600 m/min line speed. All-PEEK & FFKM seals are fully inert to toluene and xylene, enabling stable release force grading from 5 g/25mm to 50 g/25mm.
Protective Film – MRA Series (100–2000 mL/min)Positive displacement delivery ensures coating weight only depends on rotation speed, unaffected by viscosity batch fluctuation or backpressure variation. Closed-loop interlock with line speed maintains consistent adhesive thickness within ±5%, with thickness repeatability R<3% and precise peel force classification (0.05–3 N/25mm).
High Barrier Film – Parallel MPG/MRA with CANopen Modbus NetworkingMulti-pump synchronization error is controlled below 0.1% via unified pulse instructions from the master controller. Flow ratio deviation between organic and inorganic coating layers stays within ±0.5%. All-PEEK ceramic flow paths resist acidic silica sol without metal ion leaching, delivering repeatable OTR <0.1 cc/m²·day across batches.
Conductive Film – Low-shear MPG SeriesSpecially optimized low-shear gear design limits shear rate below 500 s⁻¹, preserving over 95% integrity of PEDOT:PSS polymer chains and silver nanowires. Sheet resistance remains consistent with lab syringe coating without pump-induced degradation.
HC Hard Coat – MRA Series with Zirconia Ceramic GearsWear-resistant zirconia gears withstand abrasion from nano-silica fillers in UV acrylate resin. Closed-loop feedback with online thickness gauges stabilizes wet film thickness within ±2% and guarantees pencil hardness consistency within 1H difference between batches, with over 99% scratch-free rate after steel wool abrasion test.
Anti-static Coating – MPG Series (40 μL/r) with Micro-step Servo DriveMinimum programmable injection volume reaches 2 μL per command to achieve ultra-light coating weight of 0.1–1 g/m². Surface resistivity can be accurately regulated within the target range of 10⁶–10⁹ Ω/sq without overlapping resistance grades.
One unified platform covers all six functional films and full coating weight spectrumWith identical positive displacement technology and communication protocols, equipment manufacturers avoid complex selection among peristaltic, diaphragm and screw pumps. One pump portfolio addresses all coating processes.
Multi-tooth low-pulsation design eliminates coating stripes under ultra-light coating conditionsServo closed-loop MPG pumps cut pulsation amplitude significantly, eradicating stripes on release films running at 600 m/min and ultra-thin anti-static coatings.
All-PEEK + FFKM construction compatible with all mainstream coating solventsThe inert material combination resists aromatic hydrocarbons, ketones, esters, alcohols and aqueous fluids. Lines switching between release film and HC coating only require simple flushing without pump or seal replacement.
CANopen multi-pump networking realizes precise layer matching for barrier filmsSynchronized pump rotation error below 0.1% stabilizes 5–10 alternating coating layers, eliminating reliance on manual experience to reproduce consistent OTR and WVTR performance.
Low-shear structure preserves conductive material integrity without sheet resistance lossShear rate below 500 s⁻¹ protects polymer chains and silver nanowires, balancing stable delivery and intact conductive performance for conductive film production.
20,000-hour maintenance-free operation avoids unplanned R2R line downtimeZirconia ceramic gear shafts and optional DLC-coated pump bodies achieve less than 3% flow attenuation after long continuous operation, preventing full substrate roll waste caused by pump breakdowns.
