About us - IGT · 3 Roller Combi Micro Roller 5 Roller 2 Roller Combi Engraved Roller Knife Double...
Transcript of About us - IGT · 3 Roller Combi Micro Roller 5 Roller 2 Roller Combi Engraved Roller Knife Double...
12.08.2016 © 2011 COATEMA Coating Machinery GmbH | www.coatema.de 112.08.2016 © 2015 COATEMA Coating Machinery GmbH | www.coatema.de 1
About us
12.08.2016 © 2015 COATEMA Coating Machinery GmbH | www.coatema.de 2
Summary
Introduction
Coatema
Lab, pilot and
production
tools
Technologies
& Processes
Upscaling
from Lab2Fab Summary
- Printing systems
- Scribing/Patterning systems
- Coating systems
- Coating processes
- Coating background in textiles
- Drying, curing & crosslinking
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Pilot production Standard layouts Bespoken equipment
on big scaleFab system inline
Introduction Coatema
The one stop shop solutionBatch type operation R2R on small scale Semi production on
small scale
Custom made
small scale
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Introduction Coatema
founded
1974
Film/Paper
Printed Electronics
Prepreg
Membranes
Renewables
Textile
Glass
bespokenequipment
working widths
from100 mm
up to 5,400 mm
Fro
mL
ab
2F
ab
R&Dprojects & network
worldwideservice
laminating
coating
printing
inn
ova
tio
ns
qualitymade in Germay
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Introduction Coatema
Our Headquater in Dormagen
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Introduction Coatema
Our worldwide service
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TextileFilm
Paper
RenewablesPrepreg
MembranesPrinted
Electronics
Glass
Introduction Coatema
Our markets
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Introduction Coatema
Our customers
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Introduction Coatema
Our latest awards
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Introduction Coatema
Our R&D partners
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Introduction Coatema
Our innovations through times*Projects of the last 5 years
ProLiBat
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Introduction Coatema
Our know-how
Co-Author: Andreas Giessmann
Chapter: „Anwendungen“
Author: Andreas Giessmann
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Introduction Coatema
Our business units
Lab Pilot Production Custom
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R&D Centre
Our R&D centre
Qualified personnel
Laboratories
Testing facilities
1200 qm
9 Pilot plants
1 production line
1 Click&Coat line
Working widths:
100 – 2000 mm
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customer trials to clarify
processes and parameters for
scale up of new products
pilot production of products
within the lead time of new
production lines
toll coating
Slot die impregnation and
curing of a new prepreg
material for the automotive
industry
Our R&D centre
Purpose
Example
R&D Centre
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Our R&D solution
Chemical
solution
Process
solution
Lab
solution
Coatema
solution path
Taylor-made
for your
product idea
Your
inquiry
Lab trials
R&D Centre
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Our current equipment
Multifunctional
Coatingline
Universal
Coating Plant2 x
Smartcoater
Basecoater
and inert
Bascecoater Easycoater
Filter/
Dissolver
15
Click&CoatTM
units
R&D Centre
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Lab, pilot and production tools
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Test Solution
With Slot Die
Lab, Pilot and production tools
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Test Solution R2R
Lab, Pilot and production tools
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The Easycoater
Lab, Pilot and production tools
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The Thin Film Coater & Printer
Lab, Pilot and production tools
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The Smartcoater
Lab, Pilot and production tools
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Lab, Pilot and production tools
The Basecoater 3rd Generation
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The Click&Coat
Scaling up new technologies
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R2R in nitrogen environment
Lab, Pilot and production tools
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The Deskcoater
Lab, Pilot and production tools
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The Verticoater
Lab, Pilot and production tools
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The Linecoater
Lab, Pilot and production tools
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Bespoken Lab concepts
Lab, Pilot and production tools
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Mixing equipment
Lab, Pilot and production tools
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Production lines
Lab, Pilot and production tools
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Coating Stations
Lab, Pilot and production tools
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Coating Stations
Lab, Pilot and production tools
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Coating Stations
Lab, Pilot and production tools
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Coating Lines
Lab, Pilot and production tools
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Coating Lines
Lab, Pilot and production tools
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Coating Lines
Lab, Pilot and production tools
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Coating Lines
Lab, Pilot and production tools
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Upscaling from Lab2Fab
Going to Fab - Technologies
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Technologies & Processes
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Technologies & Processes
Process Parameters
Process Parameters are:
Operation speed
Rheology of coating and printing inks
Substrate condition
Tension control MD/CD
Edge control
Resolution and registration accuracy of printing/laminating systems
Precision of coating operations
Curing / drying / crosslinking
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From Lab2Fab
Technologies & Processes
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Upscaling from Lab2Fab
Going to Fab - Technologies
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Inline Process Integration
Tension control
• load cell
• dancer
• pulling devices
• design of drives
Edge guide control
• different sensors
• mechanical stress
Registration control
• camera
• fiber optic
• design of drives
Quality control
• particle contamination analysis
• defect detection
• thickness control
• function control of the device or layer
Process analysis
• Statistic parameters
• product flow analysis
• Yield
• Cost of ownership
Technologies & Processes
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Printing Systems
Technologies & Processes
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Printing Parameters
Technologies & Processes
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Printing Parameters
Printing method Printing
speed
(m/s)
Nip
pressure
(MPa)
Ink
viscosity
(Pa·s)
Layer
thickness
(µm)
Feature
size
(µm)
Regis-
tration
(µm)
Flexography 3 – 10 0,1 – 0,5 0,01 – 0,5 0,04 – 8 40 – 80 20 – 200
Gravure 10 – 16 1,5 – 5 0,01 – 0,2 0,1 – 12 20 – 75 >10
Offset 8 – 15 0,8 – 2 1 – 100 0,5 – 3 25 – 50 >10
Screen printing 2 - 0,1 – 50 3 – 100 75 – 100 >25
Inkjet 1 – 5 - 0,001 – 0,03 0,01 - 0,5,
20 (UV)
10 – 50 <10
Technologies & Processes
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Printing Systems
Screen printingGravure printing Flexo printing
Printing Systems
Technologies & Processes
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Gravure Printing
Technologies & Processes
Gravure Printing Parameters
Printing Speed 10 - 16 m/s
Nip Pressure 1,5 - 5 MPa
Ink viscosity 0,01 - 0,2 Pa s
Layer Thickness 0,04 - 12 µm
Feature Size 20 - 75 µm
Resolution 10 - 50 µm
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Flexo Printing
Technologies & Processes
Flexo Printing Parameters
Printing Speed 3 – 10 m/s
Nip Pressure 0,1 – 0,5 MPa
Ink viscosity 0,01 - 0,5 Pa s
Layer Thickness 0,1 - 12 µm
Feature Size 40 - 80 µm
Resolution 10 - 50 µm
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Screen Printing
Technologies & Processes
Screen Printing Parameters
Printing Speed 2m/s
Nip Pressure
Ink viscosity 0,1 - 50 Pa s
Layer Thickness 3 - 100 µm
Feature Size 75 - 100 µm
Resolution 10 - 50 µm
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Registration control system
Needed for registration control:
register control camera
individual printing design of register control marks
pulling device to separate the printing process from the
winding/rewinding of the substrate
high precision side movement of printing device individual and
sensitive speed control of printing roller
pulling device in front of 1st printing station
guiding frame in front of 1st printing station
dancing roller
Technologies & Processes
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Registration control system
Technologies & Processes
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Scribing/Patterning Systems
Technologies & Processes
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Laser Patterning System
patented beam delivery for maximum precision and flexibility
integration of cw, ns, ps-laser sources – depending on application
scribing process by beam splitting from 1 to 10 parallel beams
integration of galvo-scanheads possible
full area processing of foil in / across transport direction by CNC code
Technologies & Processes
Laser Parameters
Scribing Speed
2 - 10 m/min
Structure width
10 – 75 µm
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Laser Scribing System
Height profile.
40µm wide scribe
(smaller or wider scribe is possible !!)
The build up at the scribe edge is less
than 15nm. Virtually no burr/melting
Technologies & Processes
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Laser Patterning System
Top contact TCO
Absorber1
Back contact
Barrierer
Substrat
(Metall, Polymer)
P 1
P 2
P 3
Ed
ge D
ele
te
Technologies & Processes
P 4
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Nanoimprinting System
Technologies & Processes
Nanoimpreinting Parameters
Printing Speed 0,1 - 20 m/min
Nip Pressure
Ink viscosity
Layer Thickness
Feature Size
Resolution
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Nanoimprinting System
Technologies & Processes
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Nanoimprinting System
Technologies & Processes
SiO2
Highly doped Si
wafer
SiO2SiO2
Highly doped Si
wafer
Nanoparticle
solution
A B
Highly doped Si
wafer
SiO2
PDMS moldC
Highly doped Si
wafer
SiO2
PDMS mold
80°C
5 PsiD
Highly doped Si
wafer
SiO2
Dried nanoparticles
E
Highly doped Si
wafer
SiO2
Gold
F
140°C
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Hot embossing System
Technologies & Processes
Hot embossing Parameters
Printing Speed 0,1 - 3 m/min
Nip Pressure
Register controlled
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Hot embossing System
Technologies & Processes
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Photolithographic System
Technologies & Processes
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Photolithographic System
Technologies & Processes
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Coating Systems
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Curtain CoatingSlot Die
Hotmelt Slot Die
Powder
Scatterning DippingRotary
Screen
Coating Systems
Reverse
Roll5 RollerMicro Roller3 Roller Combi
2 Roller Combi
Engraved
Roller
Case KnifeCommabarDouble SideKnife
Technologies & Processes
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Coating Parameters
Finishing
Calendaring
Embossing
Slitting
Coating
Processes
Coating systems
Single or Multilayer coatings
Direct coatings
Transfer (indirect) coatings
Substrate speed
Layer Thickness
Coating accuracy
Process control
Process layout
Tension control system
Material guiding system
Inline parameter control
Quality control
Pretreatment
Corona
Plasma
Cleaning
Substrate
Surface tension
Dimension stability
Surface structure
Contact angle
Drying
Convection drying
Contact drying
Infrared drying
Sintering
NIR
High Frequency
UV crosslinking
systems
Environment
Humidity
Temperature
Inert Conditions
Coating
Chemistry
Rheology
Viscosity
Viscoelasticity
Type of solvents
Amount of solids
Van der Waals force
Sheer ratio
Adhesion/Cohesion
Technologies & Processes
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Processes
Definition of Coating Systems
Category of
coating methods
Examples of coating
methods belong to the
category
Characteristics
Self-metered - Dip roll
- Nip forward roll
- Reverse roll
Wet thickness is determined
the conditions of the coating
meniscus
Doctored - Mayer rod
- Blade/knife
- Air knife
- Dip & scrape
Post applicator device
determines the wet thickness
Pre-metered -Slot die
- Slide curtain
- Spray
All the ink fed into an applicator
is transferred to the web
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Technologies
Slot Die System
Technologies & Processes
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Slot Die System
Slot Die Coating Parameters
Printing Speed 1 - 100 m/min
Ink viscosity 0,1 - 30.000 Pa s
Layer Thickness 0,2 - 200 µm
Coating accuracy 1 - 5 %
Technologies & Processes
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Slot Die System
OPV slot die Meniscus mode High precision slot die
Technologies & Processes
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meniscus is formed between die lips and substrate
adhesive stabilization of meniscus by die lips
very low minimum flow rate possible
range of rheological parameters limited for stability
Operating a slot die
Slot Die System
Technologies & Processes
Coating roller
Slot
die
meniscus
Distribution
chamber
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Technologies
Slot Die System
fluid
Slot Die Coating capillary stripe widening
typical
distance
100µ or
less
moving substrate or
Slot Die
with
manifold
shim
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Coating Processes
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Drying with hot air technology
Technologies
Drying Technologies
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Technologies
Drying Technologies
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1.) transfer the drying energy into solids and dryer technology
solvent to achieve the drying temperature solid heat capacity
solvent heat capacity
2.) evaporate the solvent solvent evaporation energy
solvent evaporation speed
3.) remove the solvent vapor dryer technology
Substrate
Coating
Heat transfer
Vapor removal
General tasks of drying
Drying Topics
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• combined functions of heating and
vapor transport
• bulk heating by heat transfer from
the surface
• overheating easily avoided by limited
air temperaturesimple slot dryer
wing shaped slot dryer wing shaped nozzle dryer with different nozzles
Drying systems: hot air technology
Drying Topics
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Floating dryer
single nozzle
Drying Topics
Drying systems: hot air technology
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Exhaust air Fresh air supply Dirt filter with radiator Circulation air fan
Technologies
Drying Technologies
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Technologies
Drying Technologies
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Technologies
Drying Technologies
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• separate functions of heating and
vapor transport
• full bulk heating by IR-absorption
• absorption dependant on wavelength
• overheating to be avoided by surface
temperature sensor control
• problem: temperature homogeneity
Drying systems: IR technologyIR-radiation
Drying Topics
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Courtesy Heraeus
Drying Topics
I0
I1
I0 intensity in
I1 intensity out
a absorption coefficient
x layer thickness
Drying systems: IR technology
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Technologies
Drying Technologies
IR-Sinter unit
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Combined hot air / IR dryer
Infrared dryers
Drying Topics
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• same pros and cons as IR, but even exaggerated
• complex system
• advantages for very thick layers only
Microwave dryers
Drying Topics
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COATEMA Coating Machinery GmbH
Roseller Str. 4
D-41539 Dormagen
021 33 / 97 84 – 0
YOU
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