Toray KP Films offers products of the high quality through its Vacuum Deposition technology,
slit processing, and KP seduce materials.

The interior of a Vacuum Deposition machine is divided into a winding chamber and a Vacuum Deposition chamber. Metal is heated in a high vacuum, promoting evaporation. This enables the adherence of the substance on the surface of the plastic film.

A high vacuum means there is pressure surrounding the area that creates an aurora in the space (Height: 100 to 300 km).

A Vacuum Deposition film thickness from 100 Å to 20,000 Å is possible. (10nm to 2,000 nm)

The high-frequency induction heating method

The metal is melted by heating it to approx. 1,400 to 1,500°C in a crucible.

A magnetic field is created by passing a current through the coil, and the crucible is heated.

Resistance heating method (Energized heating method)

A boat is heated and aluminum wire is continuously fed into it, resulting in Vacuum Deposition.

The metal is heated by energizing the BN composite material, which is both corrosion-proof and conducts electricity.

Electron beam method

The metal is heated by focusing an electron beam directly onto the vapor deposit metal. Unlike the other methods, the crucible or the boat is not heated.

Vacuum exhaust systems of Vacuum Deposition machinery

This achieves the high vacuum ideal for Vacuum Deposition by dividing the exhaust system into three stages.

・The high vacuum pump

The pump creates a high vacuum that enables the formation of a uniform Vacuum Deposition layer on the film.

・The medium vacuum pump

A relay pump that conveys the action to the high vacuum pump

・Roughing vacuum pump

A pump that begins evacuation from the outer air

The film is fed into the Vacuum Deposition chamber by running it through the flattening roller underneath the CC-1 (cooling roll) from the unwinding side. After the Vacuum Deposition process is finished, the film is cooled and rewound through the flattening roller.

Vacuum Deposition is possible starting from 1 µm of the thinnest film thickness.

In general, polyimides are used as the margin tape material. The tape revolves endlessly.

• We are capable of handling Vacuum Deposition for all types of patterns to improve safety and electric potential gradient.
• We are now also able to handle more complex and detailed patterns with our improved pattern roll technology.

We have 19 slitting machines.
Our advanced slitting technology meets the needs of our customers.

1）Uses

Capacitor film, release film, compound film, insulation film, magnetic tape, carrier tape

2）Characteristics

We have demonstrated our successful performance in accuracy and quality control by achieving a slit process for optional narrow widths (as narrow as 3.5 mm) for ultra-thin film.
The micro-slit is the achievement of which we are the most proud in our company’s history.

1）Uses

Optical and reflecting film, release film, packaging film, carrier film for all types of processes

2）Characteristics

We are capable of conducting the slit process in the clean room, and conducting the corona E process at the same time.
We can process up to one ton of Ø1,000 material.

1）Uses

Insulation film, carrier film for all types of processes

2）Characteristics

We are capable of slitting traverse winding on ultra-narrow film (minimum width: 0.6 mm).
We also use a trapezoidal winding to prevent tape slackening, and can handle a maximum winding length of 20,000 m.

We have large slitting machine capable of corona processing in a Class 3000 environment to meet any customer requirement for cleanliness.

We use the share cut method.
We guarantee width accuracy that cannot be obtained with the laser cut method.
We grind all our blades in house to handle any type of film slits.

We grind our blades, the critical factor for slits, in house.
There is no device that can perform a satisfactory finishing and inspection. That’s why the processes from the finish grinding to the tooth tip for each individual item are done by hand.

Corona processing is conducted on both sides of the film at the same time and slit to an optional width. Each individual film with discrepancies in material thickness is dealt with friction.

This technology improves the film surface by exposing the corona discharge to the processed film.

Effects

1.Improved adhesion

2.Improved printing

3.Improved Vacuum Deposition characteristics

4.Improved coating characteristics

5.Change in degree of surface roughness

The above effects can be obtained.