After many years of extensive development we are proud to
announce the launch of the next generation of press mat (press pad) technology.
Our new concept has embraced our own skills in the field of high performance
textiles with those of metallurgists and elastomer technologies to produce a
press compensating medium of unsurpassed performance. We are indebted to a team
of laminate manufacturers who have worked closely with us in the evaluation of
our many prototype fabrics. Their criticisms and encouragement have driven our
desires to produce a press mat (press pad) with the ultimate characteristics of
heat transfer, compensation and resilience.
THE LOGIC
Textile fibres normally used in the manufacture of press mats (press pads) cannot offer long term resistance to cycling compressive forces without permanent deformation and loss of compensation.
Logical
reasoning suggested that the substitution of an elastomer in place of textile
fibres could offer tremendous improvements in compensating ability. The
properties of high performance silicone elastomers presented a new dimension to
the science of pressure compensation.
Silicone could allow new and exciting innovations in the weaving of the mat (pad) to maximise heat transfer and compensation capabilities simultaneously.
The
changing of board sizes using the same press mat (press pad) has always been a
problem throughout the industry. This creates the so called window framing
effect - an undesirable transmission of the previous board size onto the new
production. Again, logic suggested that this problem could at least be
alleviated if not totally solved by the introduction of a silicone elastomer.
Various types of metallic alloys had to be tried because those previously used in press mats (press pads) could not accept the high stresses associated with the enhanced compensation of silicone.
Imagine the savings in inventories throughout the industry if one single design of press mat (press pad) could fulfil all needs.
The challenge was set. The technologists responded.
THE ACHIEVEMENT
The
culmination of many theories and empirical tests has resulted in a masterpiece
of textile design without the use of textile fibres.
The silicone weft encapsulates a copper wire which serves to distribute heat laterally across the mat (pad). Our product name Copsil is derived from the combination of copper and silicone in the weft.
Application of pressure produces a flat plateau with a high metallic content which considerably elevates the thermal efficiency of the mat.
Heat
transfer is a function of the thermal conductivity of the wire used in the
warp, the number of wires per unit area, and the contact efficiency of the wire
against the platen and the caul plate.
The amount of inbuilt compensation varies with the diameter of the silicone strand and the number of strands per unit of mat (pad) length.
Heat resistant tapes for securing the mats (pads) into the press can be sewn into place before despatch.
The price per square metre of Copsil is quite similar to a conventional press mat (press pad) of the same weight. Users of heavier mats (pads) could see a cost advantage when changing to Copsil.
THE UPSHOT
Compensation - Much improved on current conventional press mats (press pads) of any weight.
Working life - Loss of compensation usually terminates the operating life of any press mat (press pad). Our improvement in compensation ability also improves operating life.
Heat transfer - At least as good as conventional lightweight mats (pads) but very much better than heavier mats (pads). Platen temperatures and cycle times have been reduced in some plants.
Window framing effect - Silicone elastomer will not permanently deform under pressure. Differing board sizes can be manufactured without a problem.
Oil contamination - Water soluble degreasing of accidental oil spillage is quite possible as silicone elastomer is impervious to oil.
Shrinkage
- The mat (pad) has excellent dimensional stability and shrinkage is minimal.
Press noise reduction - This is an unexpected bonus reported by many of our trialling teams.
One design- One type and weight of press mat (press pad) will suffice for all applications previously requiring a multiplicity of types and weights.
THE FUTURE
It is hoped that the current one design philosophy will be maintained as the laminate industry moves into the Copsil era. However, the basic concept of using silicone elastomer, a material which is reluctant to take on a new configuration even after the application of intense pressure, opens up new horizons for future development.
Variations in silicone thickness and weave pattern will permit almost infinitely variable combinations of compensation and heat transfer according to the demands from the industry.
Our technologists have developed an innovative product which will bring enormous benefits to laminators in the quest for improved methods and profits. They are not resting. Further developments to find even better solutions is ongoing and will continue until all limiting boundaries have been overcome in the most economical and efficient manner. We will continue to work together with the Laminate Industry for the Laminate Industry.
Technical Specification of COPSIL ™ |
||||
| Textile Data | ||||
| Type of weave | Plain | Twill | Twill | Twill |
| Nominal fabric weight | 3100 g/m² | 3200 g/m² | 3500 g/m² | 3900 g/m² |
| Nominal metallic content by weight | 79.00% | 76.38% | 76.29% | 79.95% |
| Nominal thickness before use | 2.00mm | 2.00mm | 2.00mm | 2.00mm |
| Warp yarns per decimetre (metallic) | 84 | 83 | 83 | 114 |
| Weft yarns per decimetre (silicone) | 43 | 50 | 59 | 49 |
| Maximum available width | 3000mm | 3000mm | 3000mm | 3000mm |
| Silicone Elastomer Data | ||||
| Hardness | 70 IRHD | |||
| Colour | Clear translucent | |||
| Wall thickness | 0,4mm | |||
| Moisture and Ozone Stability | Excellent | |||
| Chemical Stability | Excellent | |||
| Oil resistance | Excellent | |||
| Flexibility temperature range | -65ºC to 265ºC | |||
| Density | 1,2 g/cm³ | |||
| Elongation at break | 300% | |||
| Cut-through resistance | Excellent | |||
| Metallurgical Data | ||||
| Warp | Brass 70/30 Alloy (BS2873) | |||
| Weft | Annealed Copper (BS4109) | |||
| Mat Performance Data | ||||
| Thermal conductivity | 0,139 W/mK (BS4745) | |||
| Thermal resistance | 0,141 tog (BS4745) | |||
| Maximum continuous temperature | 230ºC | |||
| Nominal Maximum Pressure | 100 bar | |||
| Expected number of cycles | indefinable - subject to press conditions | |||
MARATHON enjoys an enviable reputation in the laminate industry for prompt delivery of press mats (press pads) to all parts of the World.
Our emphases on the need for rapid service will ensure that COPSIL ™ is usually available for immediate despatch from stock.
This philosophy, coupled with the concept of a single mat (pad) weight, gives the user a positive opportunity to review stock levels of compensating mats (pads).
