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