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CIRUSINDUSTRIE ELEKTRONIK
Heating elements for sealing plastic films
advanced heater technology
ULTRA-PULSE sealing bars
Temperature controllersfor UPT and LPT heatsealing tools
LONG-PULSE heatsealing tools
Heating elements for sealing plastic films
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CIRUS Page 2
Contents
1. General 3
2. Structure of CIRUS heating elements 4
3. Ultra-pulse and long-pulse technology 5
3.1 Ultra-pulse technology (UPT) 5
3.2 Long-pulse technology (LPT)) 6
4. System configuration 7
5. System characteristics 8
6. Design variants of ultra-pulse heatsealing tools 11
6.1 Design variants of opposing silicone bars 12
7. Film release after the heatsealing process 13
8. Standard components 14
8.1 Linear UPT heatsealing tools in standard lengths 14
8.2 Silicone retainers in standard lengths (opposing bar) 15
8.3 Silicone profiles 16
8.4 Impulse-transformers 16
9. Other system components 17
9.1 Temperature controllers 18
9.2 Line filters, current transformer, booster, cooler 18
Contents
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CIRUS Page 3
General
1. General
CIRUS (Cermet Integrated Resistive Ultrafast Sensorless
heaters)heatsealing tools are the outcome of an ongoing development
pro-cess at ROPEX GmbH lasting many years. Extensive
experienceembracing more than 25 years as a leading supplier of
systems tocontrol the temperature of heatsealing bands laid the
foundation forthis new technology. (Patent Nos. 197 37 471 and 198
15 763)
CIRUS heatsealing tools have succeeded in overcoming the
famili-ar drawbacks of conventional film sealing tools, namely in
particular:
� The long temperature rise and cooling times
� The complex mechanical designs that are necessary:
a) To compensate thermal expansion
b) To ensure reliable current transfers
c) To avoid local overheating (coppering)
� The need to use anti-stick coverings (teflon)
� The restriction to specific formats
� The short service life
� The high costs of maintenance
� etc.
CIRUS heating elements� Are extremely dynamic
� Have no moving parts
� Dispense with anti-stick coverings
� Are format-neutral� Require no maintenance� Are durableIn
combination with specially tailored control loop components, suchas
a temperature controller (UPT/LPT-640),
impulse-transformers(ITR-x), silicone profiles, a cooler etc., they
provide ROPEX GmbHcustomers with an optimized overall system that
guarantees reliableoperation, thus saving both time and money.
Benefit from integrated, ready-to-operate solutions!
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CIRUS Page 4
Structure of CIRUS heating elements
2. Benefit from integrated, ready-to-operate solutions!
Several layers of glass-ceramic materials areapplied to a plane,
stainless steel substrateas insulation. Various layers of
glass-metalmaterials are then applied in a defined geo-metry to act
as a heating layer and for mea-suring the temperature. The final
coating is a protective cover. Each time a new layer is applied,
all the layers are sintered at +850 °C.This results in a
material-formed multilayerbond with properties previously unheard
ofin film sealing technology:
� The heating layer, which is only a few µmthick, has a very low
thermal mass andcapacity.
� The steel holder and the glass insulationhave a very low
lateral thermal conduc-tivity.
� The gap between the hot heating layerand the film is only a
few µm.
� Heating in impulse mode causes nochange in the length of the
heating layer.
� The almost unlimited choice of two-dimensional geometries for
the heatsea-ling tools make them exceptionally versa-tile (e.g.
shaped tools).
MATERIAL-FORMED BOND SINTEREDAT850°C
PROTECTIVE COVER(glass-ceramic)
HEATING LAYERMetal-glas mixture(also SENSOR)
ISOLATION(glass-ceramic)
SUBSTRATE(high-alloy steel)
WATER COOLING(not with continuousheating and some
LPTapplications)
COOLING HOLDER(sealing bar, aluminum)
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CIRUS Page 5
Ultra-pulse and long-pulse technology
3. Ultra-pulse and long-pulse technology
Two different technologies are used for CIRUS heatsealing tools,
depending on the tooldesign and mode of operation:
This technology generates heat impulses inthe region of a few
hundred milliseconds.
In addition to the UPT heatsealing tool, thesystem essentially
consists of a UPT control-ler and a water cooler for the tool. The
toolalways operates in impulse mode. It ischaracterized by
extremely short slope timesfor heating and cooling - typically
around6000° K/sec. for heating and 3000° K/sec. atthe start of the
cooling phase (e-function).
A special UPT controller ensures precise andhighly dynamic
temperature control. It is sup-ported by the low mass of the
heating layer(only a few µm thick), which simultaneouslyacts as the
sensor layer for measuring thetemperature.
Ultra-Pulse-Technology (UPT) orLong-Pulse-Technology (LPT)
3.1 Ultra-pulse technology (UPT)
The working surface for the sealing processis restricted to the
area above the heatinglayer(-> "Structure").
ROPEX GmbH offers a range of linear UPTsealing bars for use in
standard applications(-> section 8).
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CIRUS Page 6
Long-Pulse-Technology
Long-pulse technology generates heatimpulses from a few seconds
right up tocontinuous heating.
The tool has to be cooled in heat impulsemode (e.g. with air or
water), in contrast - bydefinition - with continuous heating.
The heating element consists of a heatinglayer and a separate
sensor layer for measu-ring the temperature.
The two layers are formed in a commonmanufacturing process. The
freely designa-ble heating layer geometry enables tempera-ture
profiles to be defined and created.Furthermore, it is possible to
compensateedge losses and heat sinks. The sameapplies to the sensor
layer, which can be par-tially deactivated to permit the
temperatureto be measured only at points relevant to theprocess
(Fig. b.).
The sensor layer can be applied either on thesame plane as the
heating layer or on thereverse of the substrate. The active
workingsurface (heatsealing surface) can be optio-nally on the same
plane as the heating layeror perpendicular to it.
An LPT controller specially tailored to thesystem takes care of
temperature control.
In addition to sealing film, the unit also effi-ciently
accomplishes other joining tasks,such as soldering or bonding.
LPT tools are customized solutions.
3.2 Long-pulse technology (LPT)
a.) Example of an LPT heatsealing tool with heatingand sensor
layers on one plane
b.) Example ofan LPT heats-ealing tool witha partial sensorlayer
on thereverse
Front
Reverse
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CIRUS Page 7
System configuration
4. System configuration
CIRUS heating elements, and in particularUPT heating elements,
are high-performancesystems which operate efficiently and reliab-ly
providing all the components in the controlloop are optimally tuned
to one another - andto the task at hand. Exact compliance withthe
installation and wiring instructions isessential. The system has
been evolved andoptimized by ROPEX GmbH in an intensivedevelopment
process.
Users who follow with our technical recom-mendations will profit
from the unique func-tionality of this technology, which reducesthe
customer's effort for installation, com-missioning and maintenance
to a minimum.
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CIRUS Page 8
System characteristics
5. System characteristics� Optimized thermal dynamicsThe
extremely fast temperature rise with typical slope steepnesses
of6000 °K/second, followed by rapid cooling after the heating
phase,is the outstanding feature of CIRUS ULTRA-PULSE
heatsealingtools.
The optimized thermal dynamics are the result of the physical
pro-perties and the structure of the layers, combined with the fact
thatthe heating layers are only a few µm away from the sealing
surface.Moreover, the heat for the sealing process no longer has to
penetra-te any insulating, anti-stick layers.
ULTRA-PULSE combines very short cycle timeswith previously
unattainable seal strength afterthe tool is opened plus a heatseal
that creates
an excellent visual impression.
ULTRA-PULSE heatsealing tools radiate zeroheat into the
atmosphere!
� Cold tools
The geometrically exact delimitation of the heated surface - in
con-junction with the cooled holder - results in "cold tools" in
impulsemode, in other words the sealing surface is only hot for a
few hun-dred milliseconds during the heatsealing process. A few
tenths of asecond later, it has already cooled down.
� Simple, reliable design requiring practically no
maintenance
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CIRUS Page 9
System characteristics
� Long service life
1 2 3 4 5 Mio. Zyklen
Alt
erun
g
� Format-neutral
ULTRA-PULSE heating elements allow nar-row webs of film to be
processed with longsealing bars without any problems, becausethere
is no temperature rise in the unloadedzones.
ULTRA-PULSE heating ele-ments also endure a very largenumber of
cycles under extre-me, alternating thermal loads
(impulse mode).
Partial thermal loading of theUPT heatsealing tool does
notimpair the heatseal quality in
any way.
ULTRA-PULSE heating elements dispense with wearing anti-stick
layers and are therefore
guaranteed a long service life.
� No anti-stick layersThe fact that anti-stick layers can be
dispen-sed with makes ULTRA-PULSE heatsealingtools extremely
durable and practically main-tenance-free.Since the strength of the
seal is restoredalmost instantly following the sealing pro-
cess, the film can either be simply pulledaway from the
heatsealing tool or releasedfrom it with the help of a short
impulse (->"Release impulse").
� Minimal manufacturing tolerancesThe manufacturing process has
matured over many years, leading to excellent reproducibi-lity of
the electrical and geometry data.
Ag
ing
mill. cycles
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CIRUS Page 10
System characteristics
� Temperature distribution on CIRUS heating elements
IR thermal images clear-ly reveal the extremelystable
temperature inthe longitudinal directionof a standard UPT sea-ling
bar. The "sharpn-ess" of the thermalimage towards the coldouter
zones is also easi-ly recognizable.
This thermogram showsthe temperature profileperpendicular to
theheating layer. The sym-metry about the centralaxis is plainly
visible.
An asymmetrical layerstructure allows otherthermal
cross-profiles toform in order, forinstance, to achieve aheatseal
with a larger"tail zone" - a distinctadvantage with thickfilm.
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CIRUS Page 11
Design variants of ULTRA-PULSE heatsealing tools
6. Design variants of ULTRA-PULSE heatsealing tools
ROPEX offers a standard range of linearULTRA-PULSE heatsealing
tools in variouslenghts from 200 mm to 450 mm from stock.
The components are ready to install andconnect (-> section
8), and are supplied withelectrical and cooling water connections
aswell as tapped holes for mechanical assem-bly.
Customized solutions can be developed andmanufactured alongside
the standard tools.The maximum tool size is currently 140 mmx 500
mm. Two-dimensional heatsealingband geometries are possible on this
surfacewith extensive design freedom. Low-costmultiple production
is recommended forsmall heating elements.
Combined tools with several heating layersin an integral or
modular design representanother alternative.
Integraldesign
Modulardesign
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CIRUS Page 12
Design variants of opposing silicone bars
6.1 Design variants of opposing silicone bars
In contrast with conventional heatsealingband technology, where
the sealing processis determined by the mechanical profile ofthe
band (tapered band, beaded band, T-profile band, round wire),
ULTRA-PULSEtechnology makes use of the cross-sectionalgeometry of
the silicone profile on the oppo-site side.
Flat or trim seals with differently profiled tailzones can be
created by combining differentedge geometries of the silicone
profile withdifferent elastomer
hardnesses, facilitating optimum adaptationboth to the task at
hand and to the specificproperties of the film.
In order to ensure that these processes areabsolutely reliable,
ROPEX offers precisionsilicone profiles in a variety of
hardnesseswith exact, constant cross-sectional geome-tries and the
required high temperature resi-stance. Machined aluminum bars with
tap-ped holes in the corresponding standardsealing lengths are
available for mountingthe silicone profiles (-> section 8).
Flat seal Trim seal with wide sealing zone Trim seal with narrow
sealing zone
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CIRUS Page 13
Film release
7. Film release after the heatsealing process
The adhesion on an ULTRA-PULSE tool fol-lowing the heatsealing
process varies consi-derably from one film to another.
Some types of film hardly adhere at all to thetool surface and
can therefore be releasedwithout any external assistance. Other
filmsexhibit a slight-to-moderate tendency tostick. Since the
strength of the heatseal isrestored immediately after the
sealing
process it is sufficient to apply a tensile forceto these films
in order to detach them fromthe tool surface. For example by
opening thetool with the film still clamped inside it orsimply
through the weight of the packagedproduct.
If the film adheres strongly, it can be releasedfrom the tool
subsequently by applying ashort heat impulse.
Wenn Schweiss- undKlemmschiene
geschlossen erfolgtSchweissimpuls
Nach Abk hlungbeginnt ffnen derSchweiss-Schienen
Wenn Folie durchR ckzug der
Schweiss-Schienegespannt ist erfolgt
Abl seimpuls
Abl sen der Folie undffnen der
Klemmschienen
Film release with a heat impulse (release impulse)
The sealing impulseis applied with thesealing bar and
theclamping bar clo-
sed
The sealing barbegins to open
after the tool hascooled down
A release impulse isapplied when thefilm is clamped asthe
sealing bar is
withdrawn
The film is releasedand the clamping
bar is opened
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SealingArticle
ArticleLayer width
L1 L2 L3 L4 L5 L6 L7no.
[mm][mm] [mm] [mm] [mm] [mm] [mm] [mm]
UPT-200/2,8 60 20 00 2,8 200 223 268 275 208 150 n.v.
UPT-250/2,8 60 25 00 2,8 250 273 318 325 258 200 n.v.
UPT-300/2,8 60 30 00 2,8 300 323 368 375 308 200 n.v.
UPT-350/2,8 60 35 00 2,8 350 373 418 425 358 200 n.v.
UPT-400/2,8 60 40 00 2,8 400 423 468 475 408 200 n.v.
UPT-450/2,8 60 45 00 2,8 450 473 518 525 458 200 100
CIRUS Page 14
Standard components
8. Standard componentsThe list below is only an excerpt from
ROPEX GmbH's complete product range. ROPEXGmbH reserves the right
to make technical alterations and/or improvements to all
products.
8.1 Linear UPT heatsealing tools in standard lengths
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For silicone profile width b = 6mm
ArticleArticle L1 L2 L3
no. [mm] [mm] [mm]
SH-200/6 64 20 06 211 150 n.v.
SH-250/6 64 25 06 261 200 n.v.
SH-300/6 64 30 06 311 200 n.v.
SH-350/6 64 35 06 361 200 n.v.
SH-400/6 64 40 06 411 200 n.v.
SH-450/6 64 45 06 461 200 100
For silicone profile width b = 4mm
ArticleArticle L1 L2 L3
no. [mm] [mm] [mm]
SH-200/4 64 20 04 211 150 n.v.
SH-250/4 64 25 04 261 200 n.v.
SH-300/4 64 30 04 311 200 n.v.
SH-350/4 64 35 04 361 200 n.v.
SH-400/4 64 40 04 411 200 n.v.
SH-450/4 64 45 04 461 200 100
CIRUS Page 15
Standard components
8.2 Silicone retainers in standard lengths (opposing bar)
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Trim seal profile TN 6
ArticleArticle Hardness
no. [Shore]
SF80S/TN/6 65 80 61 80
Trim seal profile TN 4
ArticleArticle- Hardness
no. [Shore]
SF80S/TN/4 65 80 41 80
Flat seal profile FN 4
ArticleArticle- Hardness
no. [Shore]
SF40S/FN/4 65 40 40 40SF60S/FN/4 65 60 40 60SF80S/FN/4 65 80 40
80
Trans-former
ITR-3/2
ITR-3/5
ITR-4.5/2
ITR-4.5/5
CIRUS Page 16
Silicone profiles
8.3 Silicone profiles
8.4 Impulse-transformersROPEX impulse-transformers are specially
optimized for supplying UPT sealing bars usedin combination with
UPT controllers.
OutputKVA
3
4,5
Dutycycle
%
20
50
20
50
Primaryvoltage
V
400v± 10%
Secondaryvoltages
V
40- 50 - 60
70- 80 - 90
Suitable forUPT
sealing bars
UPT
200 / 250 / 300
UPT
350 / 400 / 450
Remark:All silicone profiles will be delivered in thelength of
450 mm.
FN 4 TN 4
TN 6
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CIRUS Page 17
Practical examples
Practical examples
ULTRA-PULSEring heater
LONG-PULSE tool fordouble contour heatseal
ULTRA-PLUSEdouble heatsealing tool
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� Denmark / Scandinavia� Italy / Switzerland
Agents in: � U.S.A. / Canada� Mexiko / South America� South
Africa� New Zealand / Australia
Temperature controllers for CIRUS heating elements
SERIES„600“
TYPE
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AUTO
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Impulse-transformers
Line filter
Booster
Adapter for DIN railmounting
Cooler
LCD: Liquid crystal display (green) VFD: Vacuum flourescent
display (blue)
INDUSTRIE-ELEKTRONIK
ROPEX Industrie-Elektronik GmbH · Gansäcker 21 · 74321
Bietigheim-Bissingen · Germany · Tel +49 (0) 7142/7776-0 · Fax -19
· www.ropex.de · E-mail: [email protected]
Dat
a su
bje
ct t
o ch
ange
· 06
/02
Other system components (see also “Accessories“ leaflet)
Current transformer
Via ViaUPT-640-L LCD menu menu
or or� � � — —
external externalUPT-640-V VFD control analog
signal (24V) signal (0-10V)
Via ViaLPT-640-L LCD menu menu
or or� � – � �
external externalLPT-640-V VFD control analog
signal (24V) signal (0-10V)