D-Bar / E-Roll
A one-piece coating bar with no wound wire. The grooves are formed directly by thread rolling, so there is no wire breakage, spreading, or debris trapping. Produced in outer diameters of φ6–30 mm and lengths up to 7,500 mm, with film thickness adjustable from 3 ㎛ to 450 ㎛.
Overview
The difference between the one-piece D-Bar and the wound Wire-Bar
The D-Bar is a one-piece coating bar with no wound wire. Because the grooves are formed directly by thread rolling, the wire breakage, gap spreading, and debris trapping that occur with wound-wire types do not arise.
- D-Bar — easy to clean
- Wire-Bar — debris lodges in the gaps between wires
Features
Four characteristics
1. Thread rolling eliminates gap loosening and wire breakageThe pocket area (A) of the D-Bar is calculated with a combined surface roughness and profile measuring instrument. The pocket area of a wire bar is calculated by subtracting a semicircle from the rectangular section. (P = pitch mm, H = depth ㎛)
2. A form that cleans well and traps no debrisCleaning comparison conditions — coating liquid: synthetic resin paint (water-based) / cleaning method: soaked in alcohol solution for 24 hours, then wiped.
3. The land profile can be selected as neededStandard profiles S and K; special profiles R-max, W, and WP. Custom production can also change the land profile while keeping the same pocket area (standard / narrow / wide).
4. Film thickness, angle, and profile variationsThin film can be produced down to (P) 0.08 mm (H) 3 ㎛, and thick film up to (P) 1.15 mm (H) 450 ㎛. Angles from 0° to 90° are available as custom production, and special profiles such as pyramid and mesh can also be made.
Specification
Film thickness adjustment
| Thin film | Can be produced down to (P) 0.08 mm (H) 3 ㎛. | Equivalent to #0.7 |
|---|---|---|
| Thick film | Can be produced up to (P) 1.15 mm (H) 450 ㎛. | Equivalent to #119 |
| Fine adjustment | Film thickness can be adjusted across a wide range of specifications. | A range of land profiles can be machined to help control coating uniformity for different coating formulations and material properties. |
Surface treatment
◎ For other surface treatments, please inquire.
| Hard chrome plating | Film thickness from 3 ㎛ / hardness 800–900 HV / max. treatment length 7,500 mm | Friction coefficient: high |
|---|---|---|
| DLC | Film thickness 1–3 ㎛ / hardness 2,000–2,500 HV / max. treatment length 3,000 mm | Friction coefficient: low |
Production range
※1 If you require a different outer diameter, surface treatment, material, groove shape, or groove angle, please inquire.
| D — outer diameter | φ6 ~ 30 mm ※1 |
|---|---|
| L — overall length | ~ 7500 mm |
| l — groove machining range | Specified at order |
| Surface treatment | HCr, electroless Ni, DLC and others ※1 |
| Material | Stainless steel ※1 |
| Groove specification | See the separate specification table, or inquire / specifications corresponding to Wire-Bar are available |
| Edge shape | Made to suit the machine specification |
| Standard groove profile | Type S, Type K |
| Standard groove angle | Under 3° ※1 |
Why D-Bar
Advantages of thread-rolled die production
D-Bar is manufactured by thread rolling to provide a seamless profile, consistent coating quality, durability and easy cleaning.
- Produced with a thread-rolling die, so unlike wire products there is no pooling of solution or trapping of particles between wires.
- There is no spreading caused by loss of tension between wound wires, and therefore no resulting streak marks.
- Long service life.
- Easy to clean.
- The land profile and angle can be adjusted to suit the characteristics of the customer's product.
Difference in coating volume — for an equal pocket area at the groove, the D-Bar is designed with a wider pocket at the valley than a Wire-Bar, so the transfer rate is higher and the coating volume tends to be greater. ※ The size of the difference varies with the coating liquid and coating conditions. We can match the coating volume range of a Wire-Bar.
Plated surface layer — OSP's proprietary chemical plating gives excellent volume uniformity with no micro-cracks. (Hard chrome treatment produces micro-cracks.)
Quality
Precision guarantee and measurement methods
Every product must pass strict inspection criteria before shipment.
- Roundness
Three points are inspected simultaneously in the transverse direction using a tri-point micrometer.
- Runout
Both ends are supported on V-blocks and measured with a dial gauge while rotating.
- Straightness
The gap is checked with a feeler gauge while rotating.
- Cylindricity
Measured with a micrometer at three to five points.
- Groove geometry
Groove pitch, depth, pocket area, and roughness are verified with a combined surface roughness and profile meter and a super-depth microscope.
Applications
Applications
Mobile devices, polarizing plates, and the like
Release film, tape, and the like
Separators
Food, pharmaceutical, and X-ray film
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