Vacuum metallizing system CAP

plastic film

Overview
The LEYBOLD OPTICS CAP series is a roll-to-roll vacuum thin-film metalizing system designed for high-quality metallization of films used in roller-type capacitors and flexible electronics. Standard coating widths range from 500 to 900 mm.

Key benefits

• One system for many coatings: supports standard to high-end applications, thick to thin layers, plain or segmented designs, single layers or stacked layers, and a wide range of layer profiles and surface resistances.
• Effective thermal management: Leybold Optics SuperBias technology enables controlled substrate cooling for sensitive thin polymer films, improving throughput and yield.
• In-line quality assurance: DISS real-time monitoring controls layer profiles and free-margin widths to reduce scrap and ensure consistent production quality.

Highlight features

• Automated free-margin evaporator: oil evaporator generates and controls unmetalized margins in machine direction with closed-loop oil management based on margin area, winding speed and layer thickness.
• In-situ layer regulation: cross-direction and length-direction control synchronise wire feed and winding speed for uniform layer thickness across film width and length.
• Advanced aluminum evaporator: deposits aluminum layers from approx. 1 Ω/cm² up to 150 Ω/cm²; flexible height adjustment and individual source arrangement optimise uniformity and enable layer stacks.

Other features & options

• Optional pattern printing system: drawer-mounted unit combining oil evaporator, anilox and flexo roller with sleeves (structure resolution down to 0.1 mm) to produce segmented profiles and printed patterns.
• Material and process versatility: supports aluminum, aluminum/zinc, silver/zinc, heavy-edge coatings and a variety of plain, ramp or slope layer profiles.
• Typical applications: roller-type capacitors, flexible electronics, e-mobility, smart grids, renewable energy, building and energy transmission components.

Services & documentation
Bühler offers services, training and documentation to support process integration; product brochure and technical documentation available for the LEYBOLD OPTICS CAP series.

Technical specifications

• Coating method: roll-to-roll vacuum thin-film metalizing (evaporation)
• Standard coating widths: 500 mm to 900 mm
• Aluminum layer deposition range: approx. 1 Ω/cm² to 150 Ω/cm²
• Thermal management: Leybold Optics SuperBias for substrate cooling
• In-line quality control: DISS technology for real-time layer profile and free-margin width monitoring
• Automated free-margin evaporator with closed-loop oil control
• Layer regulation: cross-direction and length-direction control (wire feed and winding speed synchronization)
• Optional pattern printing: oil evaporator + anilox + flexo roller with sleeves (down to 0.1 mm)
• Supported coatings: Al, Al/Zn, Ag/Zn and multi-layer stacks