Specac Atlas GS15640 User manual

Atlas™ Constant Thickness
Film Maker Accessory
User Manual
2I-15640 Issue 6

Atlas™ Constant Thickness
Film Maker Accessory
User Manual
2I-15640 Issue 6

User Manual
2
Atlas™ Constant Thickness Film Maker
Accessory P/N GS15640
CONTENTS – USER MANUAL
1. INTRODUCTION ................................................................................. 3
2. UNPACKING AND CHECKLIST ............................................................. 4
3. SAFETY IN OPERATION ...................................................................... 5
4. THE COOLING CHAMBER ASSEMBLY .................................................. 6
5. OPERATION OF THE FILM MAKER ACCESSORY.................................... 8
PREPARING A SAMPLE FOR PRESSING ............................................... 8
THE ALUMINIUM FOIL DISCS ........................................................... 11
THE PRESSING CYCLE .................................................................... 14
HEATING THE SAMPLE .................................................................... 16
COOLING THE SAMPLE .................................................................... 16
ACCESSING THE FILM SAMPLE ........................................................ 18
6. NOTES ON OPERATION OF THE FILM MAKER ACCESSORY................ 19
NOTE 1: USING THE ALUMINIUM FOIL DISCS .................................... 19
NOTE 2: SPACER RINGS - TOLERANCES AND FILM THICKNESS ......... 19
NOTE 3: TIPS ON PRESSING ............................................................ 21
NOTE 4: CLEANING OF COMPONENTS .............................................. 22
7. LEGEND - BUBBLE NUMBER IDENTIFICATION ..................................... 23
8. SPARE PARTS FOR THE FILM MAKER ACCESSORY ............................ 23
© April 2016 Specac Ltd. All rights reserved.
Brilliant Spectroscopy is a trademark of Specac Ltd.
Other product names mentioned herein may be trademarks
of their respective owners.

Atlas™ Constant Thickness Film Maker
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1. Introduction
The Atlas™ Constant Thickness Film Maker Accessory P/N GS15640
has been designed to be used in conjunction with the Specac Atlas™
Heated Platens and Automatic Temperature Controller P/N GS15515
within the following Specac presses:-
Atlas™ Manual 15T – P/N GS15011.
Atlas™ Manual 25T – P/N GS25011.
Atlas™ Power 8T – P/N GS25400.
Atlas™ Autotouch 8T – P/N GS25800.
The Atlas™ Constant Thickness Film Maker Accessory comprises a
top and lower platen pressing assembly with a centralising guide ring
for the specific preparation of 29mm diameter films of up to 0.5mm
thickness. The thickness of the film is controlled by a specific sized
spacer ring used within and between the top and lower platen pressing
assemblies. The film thickness is also determined from any procedural
method that is adopted. Factors that influence a method are the
amount of sample introduced for pressing, the temperature and the
load applied whilst pressing.
A separate cooling chamber assembly is also provided with the Atlas™
Constant Thickness Film Maker Accessory, such that the complete
platen pressing assembly with a compressed film can be removed from
the heated platens in the press and cooled rapidly for quicker sample
preparation and handling.
The Atlas™ Constant Thickness Film Maker Accessory can be used to
melt and press polymers or plastic materials into thin films at
temperatures up to 300ºC and at loads of up to 4 Tons from the
pressing system. The samples can be prepared in this way prior to
spectral analysis via a transmission technique.

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2. Unpacking and Checklist
The Atlas™ Constant Thickness Film Maker Accessory is packed in a
protective plastic carry case. On receipt of your accessory please
check that the following have been supplied.
● One film maker system,
comprising top platen
pressing assembly,
lower platen pressing
assembly and guiding ring.
● One cooling chamber assembly.
● Set of spacer rings as listed below. These are engraved with a letter
to denote the nominal thickness of film to be produced:-
A is for 0.015mm films.
B is for 0.025mm films.
C is for 0.050mm films.
D is for 0.100mm films.
E is for 0.250mm films.
F is for 0.500mm films.
● Pack of 200 aluminium foil discs (P/N GS15627)
● Stainless steel forceps.
● Packet of 20 Specacards.
Carefully unpack the Atlas™ Constant Thickness Film Maker
Accessory parts from their carry case and proceed to use as follows.

Atlas™ Constant Thickness Film Maker
5
3. Safety in Operation
Important Note
The Atlas™ Constant Thickness Film Maker Accessory has been
designed to be as safe as possible in usage. The instructions that
follow help to advise for a safe operation, but the greatest risk to safety
may be presented by the actual sample itself to be heated and pressed
in an exposed environment. If in any doubt of the risks involved in
usage of a chemical in this way, then seek assistance.
When using the Atlas™ Constant Thickness Film Maker Accessory in
an Atlas™ Manual 15T or 25T Press (P/N’s GS15011 or P/N GS25011
respectively) although the tonnage loads to be applied for pressing are
typically low at 1 to 2 tons, with a maximum load specification to 4
tons, Specac recommend that the safety guards fitted to the Press as
standard are used at all times.
For protection against tonnage overloading the Film Maker Accessory
of parts when samples are to be pressed, it is a requirement that the
pressure relief valve assembly on a Manual Hydraulic 15T or 25T
Press (the valve is located under the load gauge on the press), is set
to read a 4 tons maximum load at the load gauge. You should adjust
the pressure relief valve assembly as necessary following instructions
for the procedure from the Presses own user instruction manual.
When using the Atlas™ Constant Thickness Film Maker Accessory in
an Atlas™ Power or Autotouch 8T Press (P/N GS25400 or P/N
GS25800 respectively), the front safety guard of the press MUST be
closed to allow for the Press to operate. The Atlas™ Constant
Thickness Film Maker Accessory has been designed to fit into these
Presses for operation when the front safety guard is closed. When
using these Presses ensure that a load of up to 4 tons maximum
ONLY is selected to apply to the Film Maker Accessory. Any higher
loads could result in damage to the Film Maker Accessory polished
pressing surfaces.

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4. The Cooling Chamber Assembly
The cooling chamber assembly (1) of the Atlas™ Constant Thickness
Film Maker Accessory is used such that the complete platen pressing
assembly (top platen assembly (2) on lower platen assembly (3)
containing a compressed hot film sample within) can be removed from
the Atlas™ Heated Platens in the press and cooled rapidly for quicker
sample preparation and handling.
For installation, the cooling chamber assembly (1) is used in
conjunction with the cooling water circuit system for use of the Atlas™
Heated Platens P/N GS15515. A cold water supply passes through the
cooling chamber assembly (1) prior to passage through the top and
lower Heated Platen assemblies fitted in the Press. The water can
pass through to a drain or be re-circulated if a suitable thermo-
circulating system has been employed for use in the water cooling
circuit. (See water cooling thermo-circulator systems, Specac P/N’s
GS11127 and GS11128.)
Fig 1. Cooling Chamber Water Connection Ports
1
4

Atlas™ Constant Thickness Film Maker
7
The cooling chamber (1) has water inlet/outlet ports (4) at the rear of
the unit and the black silicone tubing supplied with the Atlas™ Heated
Platens simply pushes on to these ribbed hose type connections.
(See Fig 1.) For additional safety, cable ties can be placed around the
tubing and hose connections to prevent the tubing from becoming
disconnected if the cooling water supply pressure is high. For
installation of the cooling chamber (1) into the water cooling circuit of
the Atlas™ Heated Platens, it does not matter which of the inlet/outlet
port (4) hose connections are connected for the water in supply and
the water out towards the Heated Platens first and then to a drain or
the thermo-circulator unit.
Note: In the instruction manual for the Atlas™ Heated Platens
(P/N GS15515) the diagram (Fig 4.) shows where the cooling
chamber (1) is connected in the water cooling circuit. It is
advisable to have the cooling chamber (1) in-line before the
cooling water passes through the Heated Platens, to try and
ensure that any cooling water will always be at its lowest
temperature when passing through the cooling chamber (1) first.

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5. Operation of the Film Maker Accessory
Follow the instructions from the user manual of the Atlas™ Heated
Platens P/N GS15515 for their installation and operation in a Specac
Press prior to use of the P/N GS15640 Atlas™ Constant Thickness
Film Maker Accessory. The cooling chamber assembly (1) should be
connected to the water cooling circuit system of the heated platens as
described in Section 4. (Pages 6 and 7 of this instruction manual.)
For the formation of a thin film from a solid plastic or polymeric type
sample when using the Film Maker Accessory, the temperature should
be set on the temperature controller of the Heated Platens to that
required for the softening and/or melting point of the sample to be
reached.
Important: A sample must be sufficiently soft or in its melted state
before any tonnage load (up to 4 tons maximum) should
be applied from the Press for pressing of the sample. If the
sample is too hard, there is a risk of point load damage
being sustained to the Film Maker Accessory parts for the
polished pressing surfaces of the top (2) and lower (3)
platen pressing assemblies.
Preparing a Sample for Pressing
The top (2) and lower (3) platen pressing assemblies of the Atlas™
Film Maker Accessory each have a highly polished circular pressing
surface (5 - top and 6 - lower). (See Fig 2.) These polished surfaces
(5) and (6) are protected from damage during transit by covering with a
plastic film. When first supplied, carefully peel off the protective film
and clean the polished surfaces (5) and (6) with a soft tissue and
suitable solvent (foam cleaner/degreaser or acetone) before use.
Similarly clean all the spacer rings (7) (sizes A through to F) before
their initial use in the formation of a thin film.

Atlas™ Constant Thickness Film Maker
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Fig 2. Top and Lower Platen Pressing Assemblies
To make a particular thickness of film sample at 29mm diameter,
select the required thickness spacer ring (7) from the six sizes
available. The spacer rings are labeled on the outer circumference
edge of the ring with an engraved letter from A to F and the letter
corresponds to the following nominal thickness of film that can be
formed.
A is for 0.015mm (15 microns) thick films.
B is for 0.025mm (25 microns) thick films.
C is for 0.050mm (50 microns) thick films.
D is for 0.100mm (100 microns) thick films.
E is for 0.250mm (250 microns) thick films.
F is for 0.500mm (500 microns) thick films.
Locate the chosen spacer ring (7) on the lower platen pressing
assembly (3) of the Film Maker Accessory, around the central raised
polished surface (6). (See Fig 3.) It does not matter which way up the
spacer ring (7) locates but it helps for a consistent sampling procedure
if the spacer ring is always located the same way up between
sampling. The orientation of the engraved letter on the spacer ring (7)
(whether it is up or down when being used) can act as a reference.
5
6
2
3

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Fig 3. Spacer Ring Fitted to Lower Platen Pressing Assembly
With the spacer ring (7) in position, take the guide ring (8) and place
this around the spacer ring (7). The smaller inner diameter edge of the
guide ring (8) contacts with the outer diameter of the spacer ring (7).
(See Fig 4.)
Fig 4. Guide Ring and Spacer Ring Fitted to Lower Platen
Pressing Assembly
The lower pressing platen assembly (3) is now ready to take an
aluminium foil/sample/aluminium foil “sandwich” for pressing.
3
7
6
3
7
6
8

Atlas™ Constant Thickness Film Maker
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The Aluminium Foil Discs
The 40mm diameter aluminium foil discs (9) are used to “sandwich” a
sample between them, before melting and pressing of the sample in
the Film Maker Accessory of parts. The spacer rings (7) have been
specifically designed to accommodate two aluminium foil disc (9)
thicknesses. One will be in contact with the top polished surface (5)
and the other in contact with the lower polished surface (6) to produce
films corresponding to a nominal thickness for the spacer ring selected.
Note: The aluminium foil discs (9) have a matt surface and a shiny
surface. Contact of a particular foil surface with the sample
whilst pressing, will determine the amount of spectroscopic
interference fringes produced by the thin film. If a reduction in
spectroscopic interference fringes is sought, the matt surfaces of
the two foils should be in contact with the sample. Conversely, if
fringes are required, (e.g. to measure the film thickness) then the
shiny surfaces should be in contact with the sample.
Place an aluminium foil disc (9) on the polished surface (6) of the lower
platen pressing assembly (3). If spectral fringes are required, the shiny
surface of the foil disc (9) should be facing uppermost. The forceps
supplied can be used to manipulate this foil into the correct position.
Fig 5. Lower Platen Pressing Assembly with Spacer Ring, Guide
Ring and Lower Aluminium Foil
9

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Take the sample to be melted and pressed and place it in the centre of
the lower foil disc (9). The amount of sample to use will vary depending
on the thickness of spacer ring (7) chosen.
Fig 6. Lower Platen Pressing Assembly with Spacer Ring, Guide
Ring, Lower Aluminium Foil and Sample
Place a second aluminium foil disc (9) over the sample and foil disc (9)
already placed on the lower platen polished pressing surface (6) of the
Film Maker Accessory. Be sure that the correct shiny surface of the top
foil disc (9) is in contact with the sample if fringes are required.
Fig 7. Lower Platen Pressing Assembly with Spacer Ring, Guide
Ring, Lower Aluminium Foil and Sample
9
Sample
9

Atlas™ Constant Thickness Film Maker
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Note: Some preliminary “test pressings” may need to be carried out
when experimenting with new and differing amounts of sample
to determine the optimum amount of the sample needed when
pressing with a specific sized spacer ring for a nominal film
thickness .When the correct amount of sample to be pressed is
known, this helps in the production process for the reproducibility
of a thin film.
Now, very carefully take the top platen pressing assembly (2) and
lower it with the top polished surface (5) coming into contact with the
top aluminium foil disc (9), using the inside of the guide ring (8) for
location. The handle (10) of the top platen pressing assembly (2)
should be located between the guiding pins (11) of the lower platen
pressing assembly (3). (See Fig 8.)
Fig 8. Complete Top Platen Pressing Assembly on Lower Platen
Pressing Assembly with Aluminium Foils and Sample
The Atlas™ Film Maker Accessory with foils and a sample is now
ready to be placed into the Atlas™ Heated Platens and Press for
melting and pressing.
2
10
11
3
8
12 13

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The Pressing Cycle
Make sure that there is a sufficient distance between the surfaces of
the Atlas™ Heated Platens in order to insert and position correctly the
prepared Atlas™ Film Maker Accessory with a sample.
Fig 9. Film Maker Accessory Assembly of Parts in an Atlas™
Manual Hydraulic Press Fitted With Atlas™ Heated Platens
Very carefully, using the handle (12) on the lower platen pressing
assembly (3), take the prepared Atlas™ Film Maker Accessory with a
sample and locate it centrally between the Atlas™ Heated Platens in
the Press. Raise the front safety guard of the Press to position the
20
2
3
21
12
10

Atlas™ Constant Thickness Film Maker
15
assembly of film maker parts between the Atlas™ Heated Platens and
then allow the front safety guard of the Press to lower and rest on top
of the handle (10) to the top platen pressing assembly (2). (See Fig 9.)
Slowly lower the top Atlas™ Heated Platen assembly (turn the lead
screw of the Press clockwise) to make contact with the upper surface
of the top platen pressing assembly (2) until all the components of
the pressing system (the top (20) and lower (21) heated platen
surfaces, top (2) and lower (3) platen pressing assemblies, aluminium
foils and sample) are just touching each other. The components should
be fairly loosely held together at this stage, prior to heating and melting
of the sample. (See Fig 9.)
Note: A tonnage load to pressurise the components together should
NOT be applied via pumping of the press piston at this time.
The components are loosely clamped together to determine the
melting point of the material to be pressed. When applying heat by
powering the Atlas™ Heated Platens, as the sample material within the
Film Maker Accessory begins to soften, the top platen pressing
assembly (2) sinks down under its own weight and a visible gap is
created between the top platen pressing assembly (2) and the top
Heated Platen pressing surface (20). Only when this phenomenon
occurs is it safe to start pressing the material via the Press piston to
apply a tonnage load. Up until this point the sample material may still
be too hard to compress and could preferentially rupture the aluminium
foil discs (9) and worse, damage the highly polished pressing faces (5)
and (6) of the top (2) and lower (3) platen pressing assemblies, even if
loads of 1 to 2 tons are applied.
However, this visual indicator point may be reached when a material
starts to soften and before it has actually reached its melting point.
The resultant film from any pressing and tonnage load application may
not be ideal. Therefore, it is most important to try and press the film at
the actual melting point of the sample to obtain the best results.
Note: If you know the melting point of the sample material to be
pressed, that can be applied as a set temperature for the
Atlas™ Heated Platens, it will help substantially in the whole
process of the thin film preparation and production.

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Heating the Sample
Select a known melting or a “test” set temperature on the controller of
the Atlas™ Heated Platens. When the set temperature has been input
and accepted, the temperature controller will power the Atlas™ Heated
Platens to reach this temperature. Wait for the softening or melt point
to be reached. (Visual identification occurs when there is a gap
between the top platen pressing assembly (2) and top heated platen
surface (20)). Then turn the lead screw of the Press clockwise to lower
the top heated platen surface (20) onto all of the components involved
in the pressing, thereby closing the gap.
Allow time for the set temperature and actual temperature to stabilise
and then apply a sufficient load from the pumping system and piston of
the Press. A maximum of 4 tons load can be applied to the Atlas™
Film Maker Accessory via the Atlas™ Heated Platens, but in most
cases a 1 or 2 tons load is more than sufficient for the preparation of
thin films. Allow the Atlas™ Film Maker Accessory assembly
components to stay at the tonnage load and actual temperature being
applied for as long as your procedure for a sample film pressing may
require. Then reduce the set temperature on the Atlas™ Heated
Platens controller back to a room temperature value (e.g. 20ºC) to stop
power being applied to the heated platen surfaces (20) and (21).
Cooling the Sample
When power is cut to the Atlas™ Heated Platens to reduce the actual
temperature and the Atlas™ Film Maker Accessory assembly
components are cooling down between the heated platen surfaces (20)
and (21), maintain the pressing load on the Accessory. You may
observe a decrease in the load on the load gauge of the Press, which
is normal when a compressed material “relaxes” on cooling. Simply re-
apply the pressing load via the piston if this effect is seen and you wish
to maintain the tonnage load that had been applied.
Note: Any effect of a tonnage load application during the cooling stage
may be considered as part of a particular procedure that is
required for the production of consistent and reproducible thin
films for the sample material type.

Atlas™ Constant Thickness Film Maker
17
When the actual temperature of the heated platen surfaces (20) and
(21) have cooled to about 100ºC below the melting and pressing
temperature, release any tonnage load that is being applied and very
carefully remove the Film Maker Accessory assembly components
from the Press to place in the cooling chamber (1). This will aid in
quicker cooling of the film to be able to handle it for mounting in the
spectrometer. (See Fig 10.)
Fig 10. Film Maker Accessory Assembly Components in Cooling
Chamber After Heating and Pressing
Beware: The handle (12) of the lower pressing platen assembly (3) is
used to transfer the Film Maker Accessory assembly
components into and out of a Press. When taking the
assembly components out of the Press if they are hot,
ensure you are wearing gloves to protect your hands.
The Film Maker Accessory assembly components may be cool to
touch after 3 to 5 minutes within the cooling chamber (1), but this
timescale is dependent upon the original temperature when
transferred. Keep the lid of the cooling chamber (1) closed between
operations to maximise the cooling effect.
1
0
12
1
3
1

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Hint: Whilst the Film Maker Accessory assembly components are
cooling down in the cooling chamber (1), if a second Film Maker
Accessory is available, this can already be prepared with a new
sample ready for melting and pressing between the Atlas™
Heated Platens. This second assembly can be placed into the
vacated Atlas™ Heated Platens for heating and pressing and in
this way the two Film Maker Accessories can be “rotated” in
operation to speed up the film making process.
During periods when the Atlas™ Heated Platens are not being used,
the top (20) and lower (21) heated platen faces should be kept close
together to maintain an even temperature for both surfaces, since the
thermocouple measuring the temperature and regulating the power
supply is inserted in the lower heated platen assembly only.
However, the same type of heating element is fitted to both the top and
lower heated platens assemblies for independent heating.
Accessing the Film Sample
After removal of the Film Maker Accessory assembly components from
the cooling chamber (1), dis-assemble the components to gain access
to the compressed film sample by lifting off the top pressing platen
assembly (2) by use of the handle (10). In most instances this should
come away easily. If some resistance to separation occurs, use the
release lever (13) provided on the right hand side of the lower pressing
platen assembly (3) to prise the components apart. (See Fig 8.)
On separation of the top platen pressing assembly (2), the pressed thin
film at 29mm diameter contained between the foil discs (9) may be
attached to either the top (5) or lower (6) polished pressing faces. The
foil “sandwich” can be removed from the top (5) or lower (6) polished
pressing faces by use of the forceps that are provided. Similarly, the
forceps can then be used to separate and peel away the foil discs (9)
from the compressed thin film sample itself.
The prepared thin film can then be mounted in a Specacard (P/N
GS03800 or P/N GS03810) or a magnetic film holder P/N GS03820 for
spectroscopic analysis.