Uploaded byJohn Glenning
Coating processes
The document discusses coating process development. It covers several key aspects of the coating process including coating formulation, coating equipment and processes, the material being coated, material handling, and drying/curing ovens. Specifically, it emphasizes the importance of uniform coating formulation, controlling coating equipment and processes, properly preparing the surface of materials to be coated, ensuring uniform material handling, and managing drying/curing oven conditions. The overall goal is to integrate these various elements to produce a consistent, high-quality coating.
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Coating processes
- 1. Coating Process Development JohnGlenning January 15, 2010
- 2. Coating Process Development Coatingis 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 Development CoatingFormulation • Uniform coating formulation within a batch, batch-to-batch & over time
- 4. Coating Process Development CoatingFormulation • Uniform coating formulation within a batch, batch-to-batch & over time • Understand the nature of the coating
- 5. Coating Process Development CoatingFormulation • 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 Development CoatingFormulation • 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 Development CoatingFormulation • 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 Development CoatingFormulation • 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 Development CoatingEquipment & Process • Extrusion coating process shears the polymer coating
- 10. Coating Process Development CoatingEquipment & 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 Development CoatingEquipment & 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 Development CoatingEquipment & 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 Development MaterialTo 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 Development MaterialTo 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 Development MaterialTo 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 Development MaterialTo 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 Development MaterialTo 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 Development MaterialHandling • Material handling is a critical component of coating
- 19. Coating Process Development MaterialHandling • Material handling is a critical component of coating • Uniform and proper tension • Coating Uniformity • Coating Adhesion
- 20. Coating Process Development MaterialHandling • 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 Development MaterialHandling • 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 Development Drying/CuringOven • More of an art form than a science
- 23. Coating Process Development Drying/CuringOven • 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 Development Drying/CuringOven • 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 Development Endof Presentation