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


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

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



Our Headquater in Dormagen



Our worldwide service


TextileFilm

Paper

RenewablesPrepreg

MembranesPrinted

Electronics

Glass


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

Lab

solution

Coatema

solution path

Taylor-made

for your

product idea

Your

inquiry

Lab trials

R&D Centre


Our current equipment

Multifunctional

Coatingline

Universal

Coating Plant2 x

Smartcoater

Basecoater

and inert

Bascecoater Easycoater

Filter/

Dissolver

15

Click&CoatTM

units

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 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



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)

P 1

P 2

P 3

Ed

ge D

ele

te


P 4


Nanoimprinting System


Nanoimpreinting Parameters

Printing Speed 0,1 - 20 m/min

Nip Pressure

Ink viscosity

Layer Thickness

Feature Size

Resolution




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


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

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



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


Technologies

Slot Die System



Slot Die System

Slot Die Coating Parameters

Printing Speed 1 - 100 m/min

Ink viscosity 0,1 - 30.000 Pa s


Coating accuracy 1 - 5 %



Slot Die System

OPV slot die Meniscus mode High precision slot die



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


Coating roller

Slot

die

meniscus

Distribution

chamber


Technologies

Slot Die System

fluid

Slot Die Coating capillary stripe widening

typical

distance

100µ or

less

moving substrate or

Slot Die

with

manifold

shim


Coating Processes


Drying with hot air technology

Technologies

Drying Technologies


Technologies

Drying Technologies


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


• 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


Floating dryer

single nozzle

Drying Topics

Drying systems: hot air technology


Exhaust air Fresh air supply Dirt filter with radiator Circulation air fan

Technologies

Drying Technologies


Technologies

Drying Technologies


• 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


Courtesy Heraeus

Drying Topics

I0

I1

I0 intensity in

I1 intensity out

a absorption coefficient

x layer thickness

Drying systems: IR technology


Technologies

Drying Technologies

IR-Sinter unit


Combined hot air / IR dryer

Infrared dryers

Drying Topics


• same pros and cons as IR, but even exaggerated

• complex system

• advantages for very thick layers only

Microwave dryers

Drying Topics


COATEMA Coating Machinery GmbH

Roseller Str. 4

D-41539 Dormagen

021 33 / 97 84 – 0

[email protected]

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

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