Roll-to-Roll Coating Operations in a Clean Room AIMCAL R2R Conference October 16, Naples, FL

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1 Operations in a Clean Room AIMCAL R2R Conference October 16, Naples, FL Clean Room Coating Solutions Dr. Ken McCarthy Clean Room Coating Solutions 151 Flint Locke Drive Duxbury, MA (C) kenclnrm@prodigy.net

2 Clean Operations Why of Interest Monday presentations Product Variety Li batteries Display coatings Photovoltaic units Digital printing Printed electronics All require uniform, clean coatings

3 Outline Cleanliness ISO Updates Measurement of Cleanliness Level Clean Environments Product performance What s acceptable? Operational Considerations Control of Static Actual Case

4 Clean Operations Several ISO Updates plus New Ones Air Cleanliness Designations tied to FS209E ISO Updates: ISO ,2:2015 ISO Cleanliness Designations ISO Testing Requirements ISO Testing Equipment Calibration

5 from Terra Universal

6 ISO :2015 Designations ISO Class 1 10 Maximum Concentration Limits (Particles/m3) 0.1 um 0.2 um 0.3 um 0.5 um 1.0 um 5.0 um FS209E ISO Class Class 1 ISO Class 3 1, Class 10 ISO Class 4 10,000 2,370 1, Class 100 ISO Class 5 100,000 23,700 10,200 3, Class 1000 ISO Class 6 1,000, , ,000 35,200 8, Class 10,000 ISO Class 7 352,000 83,200 2,930 Class 100,000 ISO Class 8 3,520, ,000 29,300 Room Air ISO Class 9 35,200,000 8,320, ,000 1 m3 = 35.3 ft3 From Particle Measuring Systems

7 1 m3 = 35.3 ft3 from Particle Measurement Systems

8 Measurement of Cleanliness Level Several commercial counters available Values measured at rest no activity; in operation equipment running; full operation includes personnel If have HEPA or ULPA filter bank for incoming air, check each filter unit at least once/year Check several points in the process Check people in clean room suits Check dryer air

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10 Clean Environments Clean Room Clean Space Clean Web Path

11 Softwall Clean Cabin from Cleanrooms International

12 Enclosed Web Path Roll-to-Roll Coating

13 Type Advantages Disadvantages Clean Room Easy machine access Cost (capital, on-going) Long tax write-off Requires most discipline Significant maintenance Clean Space Lower cost Less flexible Immediate tax write-off Intermediate maintenance Clean Web Lowest capital cost Need web conveyance Path Lowest operational cost Lowest maintenance

14 Enclosed web path may be the optimum choice If enclosed web path, need to have a mechanism to move web through the space when starting up; Same when a web break; If open the enclosed web path, i.e., clamshell ovens, may take hours to get back to the desired cleanliness level

15 Outline Cleanliness ISO Updates Measurement of Cleanliness Level Clean Environments Product performance What s acceptable? Operational Considerations Control of Static Actual Case

16 Product Performance What s Acceptable? Is ISO certification necessary for customer? Cleanliness levels for any class must be met for all operational situations (rest, equipment, personnel) Product requirements are essential Operate so that product requirements are met all the time

17 People Some Operational Considerations Air flows Materials delivery Records Visualize the process

18 People The human body is an exquisite thing but not in a clean room People generate particulates at the following rates: Standing 100,000 particles/minute Walking slowly 5,000,000 particles/minute Vigorous activity 100,000,000 particles/minute Clean room suits are essential, even beard masks

19 People

20 Air Flows Positive pressure in the coating area is necessary Laminar flow key to keeping large particles out of the air stream Dryers isolated as much as possible

21 Materials Delivery Roll packaging materials lots of particulate possibilities: remove outside clean room Vacuum rolls before entry Deliver rolls through a lock if possible Minimize any other materials Roll cores are often overlooked

22 Records Try to not have any in the clean area Use computers or terminals to record information Use clean room paper if need written records Overlaminate diagrams, procedures, and protocols

23 Cleaning Procedures For Class 6 and lower Clean floor and horizontal surfaces frequently, at least weekly Minimize cleaning residues Water best to finish Care here pays off in product quality

24 Follow a Roll Envision yourself sitting on a roll (shrunken down to 1 mm) Follow through the process Where does the roll come in contact with dirt,debris 2 Cases of questionable practices: Roll put on the floor and rolled to the unwind Two step coating with slitting in the warehouse in between

25 Need a clean spirit throughout the organization Cannot have dirt laden material in or near the coating process Cannot have material control or business processes entering the clean area

26 Control of Static How static is generated Problems with static Measurement of static Control of static

27 Static Generation Static charges generated any time two materials separate Amount of charge remaining depends on conductance of material surface Static charges are not good for coating in a clean room

28 Problems with Static Many substrates used in coating are excellent dielectrics, eg., PET As such, they can hold large amounts of charge Measured potentials of 10-20,000 volts are common Charges in this range attract particulates Oil droplets can be pulled from 1-2 feet away from the substrate

29 Measurement of Static Need to know where you are Buy or rent a static meter Measure levels throughout the machine Changes in speed or substrate can change static levels Kelly Robinson

30 Control of Static Change materials difficult to do Substrate with an antistat added or coated Most effective, but more cost May not be compatible with product Add static control measures Humidity control Static brushes or wires Ionized air Ionizing sources, eg., Americium bars, with safety first

31 Actual Case Mystery Contaminant Contamination Losses % Lost A-shift B-shift C-shift

32 Contamination Occurrence Defect Frequency Time in a Roll (On-line defect detector)

33 Problem Solving Techniques Kepner Tregoe Cause and Effect Diagram Failure Mode Effect Analysis OOTF: Out on the Floor

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37 What s Really Important? Good equipment Good protocols Good training Pay attention to details

38 Thank you Questions?