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
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
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 âover cleanâ or âover dryâ
⢠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 âover cleanâ or âover dryâ
⢠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 âover cleanâ or âover dryâ
⢠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 âover cleanâ or âover dryâ
⢠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
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
⢠Good Viscosity and temperature control of the coating
⢠Uniform and proper tracking
⢠Coating Thickness
⢠Coating Uniformity
⢠Coating Adhesion
23. Coating Process Development
Drying/Curing Oven
⢠More of an art form than a science
⢠Surface âskinningâ
⢠Trap solvents
⢠Slow down drying
⢠Surface damage due to âblisteringâ
⢠Heat from the bottom up
24. Coating Process Development
Drying/Curing Oven
⢠More of an art form than a science
⢠Surface âskinningâ
⢠Trap solvents
⢠Slow down drying
⢠Surface damage due to âblisteringâ
⢠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