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Coating Processes Development

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How to ensure coating processes are robust, reliable, cost effective and produce products of high quality consistently

How to ensure coating processes are robust, reliable, cost effective and produce products of high quality consistently

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  • 1. Coating Process DevelopmentCoating Process Development John GlenningJohn Glenning January 15, 2010January 15, 2010
  • 2. Coating Process DevelopmentCoating Process Development Coating is a complex operation • Integration of materials, equipment and processes • Coating Formulation • Coating Equipment and Process • Surface of the film to be coated • Transportation of the film through the process • Drying/Curing of the coating
  • 3. Coating Process DevelopmentCoating Process Development Coating Formulation • Uniform coating formulation within a batch, batch-to-batch & over time
  • 4. Coating Process DevelopmentCoating Process Development Coating Formulation • Uniform coating formulation within a batch, batch-to-batch & over time • Understand the nature of the coating
  • 5. Coating Process DevelopmentCoating Process Development Coating Formulation • Uniform coating formulation within a batch, batch-to-batch & over time • Understand the nature of the coating • Newtonian Fluid: The viscosity of the fluid is independent on the forces acting on the fluid (water)
  • 6. Coating Process DevelopmentCoating Process Development Coating Formulation • Uniform coating formulation within a batch, batch-to-batch & over time • Understand the nature of the coating • Newtonian Fluid: The viscosity of the fluid is independent on the forces acting on the fluid (water) • Non-Newtonian Fluid: The viscosity of the fluid is dependent on the forces acting on the fluid (polymers)
  • 7. Coating Process DevelopmentCoating Process Development Coating Formulation • Uniform coating formulation within a batch, batch-to-batch & over time • Understand the nature of the coating • Newtonian Fluid: The viscosity of the fluid is independent on the forces acting on the fluid (water) • Non-Newtonian Fluid: The viscosity of the fluid is dependent on the forces acting on the fluid (polymers) • Thixotropic: Viscosity decreases with increasing rate of shear over time (ketchup) • Pseudoplastic: Viscosity decreases with increasing rate of shear independent of time (paint) • Rheopectic: Viscosity increases with increasing rate of shear over time (pastes) • Dilatant: Viscosity increases with increasing rate of shear independent of time (corn starch and water)
  • 8. Coating Process DevelopmentCoating Process Development Coating Formulation • Uniform coating formulation within a batch, batch-to-batch & over time • Understand the nature of the coating • Newtonian Fluid: The viscosity of the fluid is independent on the forces acting on the fluid (water) • Non-Newtonian Fluid: The viscosity of the fluid is dependent on the forces acting on the fluid (polymers) • Thixotropic: Viscosity decreases with increasing rate of shear over time (ketchup) • Pseudoplastic: Viscosity decreases with increasing rate of shear independent of time (paint) • Rheopectic: Viscosity increases with increasing rate of shear over time (pastes) • Dilatant: Viscosity increases with increasing rate of shear independent of time (corn starch and water) • Impact process equipment that manufactures a wide range of products
  • 9. Coating Process DevelopmentCoating Process Development Coating Equipment & Process   • Extrusion coating process shears the polymer coating
  • 10. Coating Process DevelopmentCoating Process Development Coating Equipment & Process   • Extrusion coating process shears the polymer coating • Shearing applies stresses to the coating material • Coating performance depends on the type of coating
  • 11. Coating Process DevelopmentCoating Process Development Coating Equipment & Process   • Extrusion coating process shears the polymer coating • Shearing applies stresses to the coating material • Coating performance depends on the type of coating • Control the coating process and equipment • Uniform & proper gap in space and time • Uniform & proper vacuum in space and time • Uniform & proper flow rate in space and time • Uniform & proper coating temperature in space and time • Uniform & proper solids concentration in space and time
  • 12. Coating Process DevelopmentCoating Process Development Coating Equipment & Process   • Extrusion coating process shears the polymer coating • Shearing applies stresses to the coating material • Coating performance depends on the type of coating • Control the coating process and equipment • Uniform & proper gap in space and time • Uniform & proper vacuum in space and time • Uniform & proper flow rate in space and time • Uniform & proper coating temperature in space and time • Uniform & proper solids concentration in space and time • Season change impacts coating processes
  • 13. Coating Process DevelopmentCoating Process Development Material To Be Coated   • Surface conditions are critical • Low and uniform surface tension • Surface tension too high: Delamination • Uniform surface tension: Uniform coating thicknesses
  • 14. Coating Process DevelopmentCoating Process Development Material To Be Coated   • Surface conditions are critical • Low and uniform surface tension • Surface tension too high: Delamination • Uniform surface tension: Uniform coating thicknesses • Prepare the surface: Cannot “over clean” or “over dry” • Remove oils • Remove debris • Remove oxides • Dry the surface • How fast do oxides reform
  • 15. Coating Process DevelopmentCoating Process Development Material To Be Coated   • Surface conditions are critical • Low and uniform surface tension • Surface tension too high: Delamination • Uniform surface tension: Uniform coating thicknesses • Prepare the surface: Cannot “over clean” or “over dry” • Remove oils • Remove debris • Remove oxides • Dry the surface • How fast do oxides reform • Coat immediately after the surface is dried
  • 16. Coating Process DevelopmentCoating Process Development Material To Be Coated   • Surface conditions are critical • Low and uniform surface tension • Surface tension too high: Delamination • Uniform surface tension: Uniform coating thicknesses • Prepare the surface: Cannot “over clean” or “over dry” • Remove oils • Remove debris • Remove oxides • Dry the surface • How fast do oxides reform • Coat immediately after the surface is dried • Does the material being coated out-gasses: Delamination
  • 17. Coating Process DevelopmentCoating Process Development Material To Be Coated   • Surface conditions are critical • Low and uniform surface tension • Surface tension too high: Delamination • Uniform surface tension: Uniform coating thicknesses • Prepare the surface: Cannot “over clean” or “over dry” • Remove oils • Remove debris • Remove oxides • Dry the surface • How fast do oxides reform • Coat immediately after the surface is dried • Does the material being coated out-gasses: Delamination • Microetch the surface-Increasing the surface area
  • 18. Coating Process DevelopmentCoating Process Development Material Handling   • Material handling is a critical component of coating
  • 19. Coating Process DevelopmentCoating Process Development Material Handling   • Material handling is a critical component of coating • Uniform and proper tension • Coating Uniformity • Coating Adhesion
  • 20. Coating Process DevelopmentCoating Process Development Material Handling   • Material handling is a critical component of coating • Uniform and proper tension • Coating Uniformity • Coating Adhesion • Uniform and proper line speed • Coating Thickness • Coating Uniformity
  • 21. Coating Process DevelopmentCoating Process Development Material Handling   • Material handling is a critical component of coating • Uniform and proper tension • Coating Uniformity • Coating Adhesion • Uniform and proper line speed • Coating Thickness • Coating Uniformity • Uniform and proper tracking • Coating Thickness • Coating Uniformity • Coating Adhesion
  • 22. Coating Process DevelopmentCoating Process Development Drying/Curing Oven   • More of an art form than a science
  • 23. Coating Process DevelopmentCoating Process Development Drying/Curing Oven   • More of an art form than a science • Surface “skinning” • Trap solvents • Slow down drying • Surface damage due to “blistering” • Heat from the bottom up
  • 24. Coating Process DevelopmentCoating Process Development Drying/Curing Oven   • More of an art form than a science • Surface “skinning” • Trap solvents • Slow down drying • Surface damage due to “blistering” • Heat from the bottom up • Air Flow • Coating damage due to air flow: Turbulent Flow • Break-up the boundary layer: Laminar flow • Rapid air exchange in the oven • No eddy currents in the oven • Counter-current air flow
  • 25. Coating Process DevelopmentCoating Process Development End of Presentation