Color Laser Film can be marked at speeds to 3,000 mm/sec.
August 18, 2008 -
Suitable for Nd:YAG, Vanadat, and fiber laser systems, Color Laser Film features modular design, where laser beam first penetrates laminate layer before hitting laser-active layer, which exposes colored layer of ink underneath. Marking process occurs emission-free inside film composite. Both UV- and weather-resistant, transparent laminate layer provides permanent protection of all data on label. Individual polymer layers are temperature-resistant from -40 to +130°C.
The days of the conventional metal nameplate are over. For efficient component labeling, automobile and machine manufacturers now increasingly opt for laser-markable film labels. These innovative special labels are flexible in terms of shape and size, suitable for customized laser marking, and enable in-process creation of the label and application to the component. This reduces manufacturing process complexity and achieves long-term cost savings.
Self-adhesive labels have long been in use as alternatives to metal nameplates. They are delivered to the production line either as pre-printed labels or are individually marked using thermal transfer printing. While thermal transfer printing is a comparatively low-cost process, it frequently fails to meet the customer's requirements regarding resistance and flexibility. Protection of the labels from external influences requires overlamination after printing. To ensure that the label and the protection film fit together, the size and shape of both are pre-defined, which reduces flexibility. This is where the benefits of laser marking come into play, because the laser beam is used for both marking and cutting the labels from the film stock in the required shape and size, which results in higher flexibility and leaner processing.
However, in the conventional laser marking process the laser beam ablates the top layer of the plastic film at precisely defined places, exposing the layer of ink underneath. As the exposed ink is no longer protected by a layer of film, it is vulnerable to mechanical abrasion. In addition, the ablation process emits dust and gases, which means that maintenance-intensive exhaust systems are required even for die-cut labels. Therefore, Schreiner ProTech developed Color Laser Film (CLF), an innovative film, which exhibits none of these disadvantages and harnesses the entire technical potential of laser marking technology.
Emission-free and Durable
The CLF principle is both simple and ingenious: instead of ablating the top layer of the film, the laser energy triggers a conversion process. Therefore, Schreiner ProTech's CLF features a modular design. Without destroying it, the laser beam first penetrates a transparent laminate layer before hitting the laser-active layer, where the energy is absorbed. The reaction of the laser-active layer exposes the colored layer of ink underneath. The film composite is complemented by a layer of adhesive, which is adapted precisely to the respective substrate and the customer's requirements.
Therefore, the drawbacks of conventional laser marking are a thing of the past. The marking process of the Color Laser Film occurs completely emission-free inside the film composite. This means that costly and maintenance-intensive exhaust systems for marking die-cut labels are not required. In addition, the transparent laminate layer provides reliable, permanent protection of all the data on the label from mechanical abrasion and other external influences. The individual polymer layers are highly temperature-resistant from -40 to +130 °C or, for short-term exposure, up +150 °C. The material composite is both UV- and weather-resistant and achieves a service life of up to 15 years, in line with industry requirements.
All commercially available Nd:YAG-, Vanadat and fiber laser systems can be used. The innovative marking process by means of conversion instead of ablation consumes much less energy than the ablation process and is considerably faster. Schreiner ProTech's CLF can be marked at speeds of up to 3,000 mm per second, with high edge definition and precision. The film's modular construction offers a broad choice of material versions and colors. In addition, the Color Laser Film can be repositioned immediately after application. This enhances processing comfort, minimizes errors, and saves material.
Schreiner ProTech's CLF also sets standards in terms of security and authenticity protection, an aspect that is becoming increasingly important in view of the rising incidence of product piracy. The Color Laser Film can be provided with predetermined breaking points, which prevent any non-destructive removal of the label shortly after application to the component. Additionally, the label can be equipped with customized features such as an integrated logo, micro-font that is invisible to the naked eye, holograms, or color-shifting effects.
Bosch Success Story: CLF with Integrated Paint Mask
CLF is being used successfully in numerous field applications. An impressive case in point is Robert Bosch GmbH. The automotive supplier produces injection pumps for fuel-efficient common rail diesel engines. To make the manufacturing process more efficient, Schreiner ProTech developed a multifunctional CLF family sheet for rail and pump rating plates, which replaces the previously used aluminum plates riveted to the components in a complex process.
The project specified exacting requirements. The CLF labels had to exhibit high chemical and temperature resistance to withstand oil and washing baths up to 120° C and to provide reliable adhesion to the rough gray cast iron component surface. The nameplate was to be scratch-proof and wipe-resistant, enable flexible marking with variable data, and ensure automatic readability of barcodes and 2D codes across the manufacturing process. Schreiner ProTech developed a CLF with integrated paint mask for the project. The label remains on the component throughout the manufacturing process, can be marked with variable data through a paint mask, and thereby improves process control. After the painting process, the paint mask is simply peeled off by hand. Bosch summed up the results of the project: "The new CLF family sheet has enabled us to reduce the number of process steps and material costs. In addition, component traceability has been improved."
Opel Success Story: Flexible Marking with CLF
Opel is another manufacturer who has clearly reduced manufacturing costs and complexity by adopting a Schreiner ProTech CLF solution. The innovative laser film is used in the production of the Opel Corsa. The popular sub-compact car comes in numerous versions. Therefore, in the past, a large number of different nameplates had to be designed, tested, stocked, and staged "just-in-time" at the respective production stations. This diversity involved a wide range of materials and different suppliers requiring a complex coordination, material management, and logistics process. A flexible CLF family sheet by Schreiner ProTech addressed these issues and provided an effective solution.
The so-called Flexible Label System now enables Opel to generate all the vehicle-specific data, such as the vehicle identification number (VIN), tire inflation pressure or weight, directly at the final assembly line. The laser system simply calls the data from the Opel production system and creates the complete label set "just-in-time" for each Corsa unit. This clearly simplifies the marking process and achieves significant cost savings.
Conclusion: The Future belongs to CLF
The future of industrial labeling belongs to Color Laser Film. Schreiner ProTech's innovation harnesses high levels of potential savings by making processes leaner. At the same time, it delivers convincing quality, security, and durability as well as an extremely broad range of customization options.
BU (Family Sheet)
Instead of ablating the top layer of the film, the laser energy triggers a conversion process.
BU Opel:
The flexible CLF family sheet dramatically reduced the logistics requirements at the production stations.
BU Bosch:
The multi-functional CLF rating plate for rails and pumps has replaced the previously used aluminum plates riveted to the components in a complex process.
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