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.

1. Coating Process Development
John Glenning
January 15, 2010

2. Coating 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 Development
Coating Formulation
• Uniform coating formulation within a batch, batch-to-batch & over time

4. Coating Process Development
Coating Formulation
• Uniform coating formulation within a batch, batch-to-batch & over time
• Understand the nature of the coating

5. Coating 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 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 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 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 Development
Coating Equipment & Process
• Extrusion coating process shears the polymer coating

10. Coating 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 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 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 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 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 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 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 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 Development
Material Handling
• Material handling is a critical component of coating

19. Coating Process Development
Material Handling
• Material handling is a critical component of coating
• Uniform and proper tension
• Coating Uniformity
• Coating Adhesion

20. Coating 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 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 Development
Drying/Curing Oven
• More of an art form than a science

23. Coating 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 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 Development
End of Presentation