Industry News

The common internal structures of heating rollers can be broadly categorized into five main types: 1.Single-Inlet, Single-Flow Structure with Spiral Channels 2.Single-Inlet, Dual-Flow Structure with a Tank-style Interior and Spiral Channels 3.Dual-Inlet, Dual-Flow Structure with Internal Spiral Channels 4.Dual-Inlet, Dual-Flow Structure with Extended Spiral Circulation 5.Counter-flow Internal Spiral Channel Structure

Industries with an almost rigid requirement for ultra-low roughness mirror rollers include: • Optical thin film industry (Ra ≤0.05 μm) • Electronic materials industry (Ra 0.03–0.08 μm) • Precision coating industry (Ra ≤0.05–0.1 μm) • High-end functional films and high-gloss packaging films • High-precision metal foil processing

Many people believe that as long as the mirror roller is polished to a sufficiently bright and smooth state, it must be the optimal state. However, in industrial applications, this understanding is one-sided. If the roughness is not set properly, even if the mirror roller itself has high machining precision, it may lead to production problems.

From an engineering perspective: Industrial Heated Roller Too small size • Insufficient heat capacity • Large temperature fluctuations • Poor mechanical rigidity Too large size • Slow heating • High energy consumption • Increased manufacturing and maintenance difficulty

Common defects include: • Softening of the product surface, making it difficult to stabilize its shape • Inaccurate dimensional control, with fluctuations in thickness or width • Surface stretching marks or slight deformation

Unlike chromium-plated rollers, the working surface of a tungsten carbide coated roller is not metallic chromium, but a composite structure composed of high-hardness ceramic phase particles and a bonding phase. This is the fundamental premise for why tungsten carbide coated rollers are considered "more wear-resistant."

Compared to traditional thick-walled rollers, thin-walled rollers typically possess the following characteristics: • Relatively thinner roller wall thickness • Lighter overall weight • Lower heat capacity • Faster thermal response • Higher requirements for design and manufacturing precision

In most industrial applications, the surface roughness (Ra) of cast film rollers generally falls within the following ranges: • Mirror finish: Ra ≤ 0.05 μm • High gloss finish: Ra ≈ 0.05 – 0.1 μm • Functional finish: Ra ≈ 0.1 – 0.4 μm

Common heating media for industrial heated rollers include: 1. Thermal oil (most common) 2. Electric heating (no medium required, self-contained system) 3. Steam 4. Hot water 5. Molten salt heating medium 6. Other special media (such as air, gas, heat pipe technology, etc.)

Currently, the commonly used roughness measurement methods for industrial mirror rollers mainly include: 1. Contact roughness tester (most commonly used) 2. Non-contact optical roughness test 3. Interferometer test (high-precision mirror-level) 4. Three-dimensional surface topography scanning method 5. White light interferometry for nanoscale roughness detection 6. Profilometer for complex textured mirror rollers