GBC Ultima 65 Service Manual Download

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5.0 TROUBLESHOOTING

5.1

Theory of Operation

The laminator uses heat, pressure, tension and speed to continuously apply adhesive coated
laminating film to both sides of sheet type materials simultaneously. Both electrical and
mechanical properties of this laminator are described in this section. Electrical schematics and
wiring diagrams are also provided in this section. A basic understanding of the theory of
successful lamination is required for all personnel servicing the Ultima 65.

5.2

Theory of Successful Lamination

To obtain the ultimate in a successful laminate, three factors should be present:

1. The product to be laminated should be receptive to, and capable of attaining, a good bond with

molten polyethylene adhesive.

Most paper products can be laminated with a high degree of integrity. This is because molten
polyethylene cements to individual fibers of the paper surface. The rougher the surface texture,
the more fibers are exposed to adhesive and the better the bond between adhesive and product.
Many substances are applied to paper products, which impair bond between fibers and the
molten adhesive. Ink and other printing products affect this bond. While good adhesion occurs
between molten adhesive and ink, poor adhesion may exist between ink and its parent paper.
Some ink products are heat sensitive and/or lack the ability to be bonded by certain lamination
processes. This may require the use of pressure sensitive adhesive (PSA), NAP-LAM II, Vinyl,
Premium or HI-TAC type film products.

Some paper and card stocks are coated with silicones, wax or varnish, which inhibit the ability
of molten polyethylene to stick tightly to individual paper fibers. In such cases, a superficial
bond develops which may be adequate, depending upon intended use of the finished laminate.

Smooth surfaces, especially photographic, metallic, and plastic, are difficult for polyethylene to
bond to, since no fibers are exposed for the adhesive to contact. This may require the use of
other film products to laminate correctly.

Products containing moisture will not laminate well since the fluid converts to steam, forms
bubbles, and impairs lamination.

2. At the moment of lamination, the product - polyethylene interface - both top and bottom, must

reach the lamination film’s proper operating temperature. Superficial bonds develop at lower
temperatures, and the finished laminate may be adequate for its intended use. However, for
proper lamination please consult the lamination guide in section 10.Thickness/color of a
product bears heavily on the ultimate integrity of the bond, since the thicker/darker a product;
the more heat is extracted from the heat rolls. Thicker/darker products may extract heat faster
than the machine can put in, and after 20 feet or so, the interfacial temperature may drop below
the critical point. Generally speaking, most card stocks whose thickness is on the order of
0.012” thick can be laminated on a continuous basis.

5-1