About us - IGT · 3 Roller Combi Micro Roller 5 Roller 2 Roller Combi Engraved Roller Knife Double...

About us

Summary

Introduction

Coatema

Lab, pilot and

production

Technologies

& Processes

Upscaling

from Lab2Fab Summary

- Printing systems

- Scribing/Patterning systems

- Coating systems

- Coating processes

- Coating background in textiles

- Drying, curing & crosslinking

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

founded

Film/Paper

Printed Electronics

Prepreg

Membranes

Renewables

Textile

bespokenequipment

working widths

from100 mm

up to 5,400 mm

R&Dprojects & network

worldwideservice

laminating

coating

printing

qualitymade in Germay

Our Headquater in Dormagen

Our worldwide service

TextileFilm

RenewablesPrepreg

MembranesPrinted

Electronics

Our markets

Our customers

Our latest awards

Our R&D partners

Our innovations through times*Projects of the last 5 years

ProLiBat

Our know-how

Co-Author: Andreas Giessmann

Chapter: „Anwendungen“

Author: Andreas Giessmann

Our business units

Lab Pilot Production Custom

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

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

Our R&D solution

Chemical

solution

Process

solution

Coatema

solution path

Taylor-made

for your

product idea

inquiry

Lab trials

R&D Centre

Our current equipment

Multifunctional

Coatingline

Universal

Coating Plant2 x

Smartcoater

Basecoater

and inert

Bascecoater Easycoater

Filter/

Dissolver

Click&CoatTM

R&D Centre

Lab, pilot and production tools

Test Solution

With Slot Die

Lab, Pilot and production tools

Test Solution R2R

The Easycoater

The Thin Film Coater & Printer

The Smartcoater

The Basecoater 3rd Generation

The Click&Coat

Scaling up new technologies

R2R in nitrogen environment

The Deskcoater

The Verticoater

The Linecoater

Bespoken Lab concepts

Mixing equipment

Production lines

Coating Stations

Coating Lines

Upscaling from Lab2Fab

Going to Fab - Technologies

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

From Lab2Fab

Upscaling from Lab2Fab

Going to Fab - Technologies

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

Printing Systems

Printing Parameters

Printing method Printing

pressure

viscosity

(Pa·s)

thickness

Feature

Regis-

tration

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

Printing Systems

Screen printingGravure printing Flexo printing

Printing Systems

Gravure Printing

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

Flexo Printing

Flexo Printing Parameters

Printing Speed 3 – 10 m/s

Nip Pressure 0,1 – 0,5 MPa

Ink viscosity 0,01 - 0,5 Pa s

Screen Printing

Screen Printing Parameters

Printing Speed 2m/s

Nip Pressure

Ink viscosity 0,1 - 50 Pa s

Layer Thickness 3 - 100 µm

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

Registration control system

Scribing/Patterning Systems

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

Laser Parameters

Scribing Speed

2 - 10 m/min

Structure width

10 – 75 µm

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

Laser Patterning System

Top contact TCO

Absorber1

Back contact

Barrierer

Substrat

(Metall, Polymer)

Nanoimprinting System

Nanoimpreinting Parameters

Printing Speed 0,1 - 20 m/min

Nip Pressure

Ink viscosity

Layer Thickness

Feature Size

Resolution

Highly doped Si

SiO2SiO2

Highly doped Si

Nanoparticle

solution

Highly doped Si

PDMS moldC

Highly doped Si

PDMS mold

5 PsiD

Highly doped Si

Dried nanoparticles

Highly doped Si

140°C

Hot embossing System

Hot embossing Parameters

Printing Speed 0,1 - 3 m/min

Nip Pressure

Register controlled

Hot embossing System

Photolithographic System

Coating Systems

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

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

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

Processes

Definition of Coating Systems

Category of

coating methods

Examples of coating

methods belong to the

About us - IGT · 3 Roller Combi Micro Roller 5 Roller 2 Roller Combi Engraved Roller Knife Double...

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