Optimization of equipment and process conditions for film winding

Mathematical modeling of film winding has progressed to a point where it can offer much insight into the mechanics of this process. However, experience and testing on the actual hardware are still necessary to maximize yields. The purpose of this work is to describe the practice of using both modeling and testing in consort to optimize winding. Modeling is the first step. For the best results, this is done before the winding hardware is fabricated. The use of models for roll stresses, air entrainment, buckling, air leakage and roll aging are discussed. Films are divided into categories based on the predominant defect type. Winding hardware and film surface design requirements are discussed for each of these film groups. An example of this approach is included that describes the process from the concept to on-line testing phases to optimize the process conditions