Production methods for large area printed electronics and beyond. Thomas Kolbusch, Vice President

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1 Production methods for large area printed electronics and beyond Thomas Kolbusch, Vice President COATEMA Coating Machinery GmbH 1

2 Connect Like Follow COATEMA Coating Machinery GmbH 2

3 Summary Introduction Coatema The printed electronics market? Scaling up new technologies Proof of concept Printing & Coating Laser Patterning Nano Imprinting Summary COATEMA Coating Machinery GmbH 3

4 Introduction Coatema COATEMA Coating Machinery GmbH 4

5 innovations Introduction Coatema quality made in Germay working widths from100 mm coating bespoken equipment up to 5,400 mm printing laminating founded 1974 Film/Paper Printed Electronics Prepreg Membranes Renewables Textile Glass From Lab2Fab R&D projects & network worldwide service COATEMA Coating Machinery GmbH 5

6 Introduction Coatema Our customers COATEMA Coating Machinery GmbH 6

7 Introduction Coatema Our R&D partners COATEMA Coating Machinery GmbH 7

8 Introduction Coatema Our innovations through times Projects of the last 5 years ProLiBat Flexensys COATEMA Coating Machinery GmbH 8

9 Introduction Coatema Our R&D centre 1200 qm 12 Pilot plants 1 production line 1 Click&Coat line Working widths: mm Qualified personnel Laboratories Testing facilities COATEMA Coating Machinery GmbH 9

10 Introduction Coatema The one stop shop solution Batch type operation R2R on small scale Semi production on small scale Custom made small scale Pilot production Standard layouts Bespoken equipment on big scale Fab system inline COATEMA Coating Machinery GmbH 10

11 What does printed electronics mean? COATEMA Coating Machinery GmbH 11

12 Case Study The future market Billion US$ predominantly by OLED displays Billion US$ predominantly by OLED displays Potential for a 50 Billion US $ market within the next 10 years driven by OPV, lighting, displays, logic, memory/rfid, sensors COATEMA Coating Machinery GmbH 12

13 Speed of development Expectations Strategy Surf Hype cycle Trigger Peak Enlightment Plateau of productivity Disillusion Time Speed to market COATEMA Coating Machinery GmbH 13

14 Strategy Products / Processes Display Transistor Printing Laser Memory Nano imprint Printed Devices RFID Coating Fuel Cell NFC Battery Solar COATEMA Coating Machinery GmbH 14

15 Strategy Equipment Bespoken Production Test Solution C&C Printed Devices Easycoater Base coater Smart coater Services Thinfilm coater COATEMA Coating Machinery GmbH 15

16 Case Study The future market COATEMA Coating Machinery GmbH 16

17 Case Study The future market COATEMA Coating Machinery GmbH 17

18 Picture sources: Fraunhofer ISE Case Study The future market COATEMA Coating Machinery GmbH 18

19 Scaling up new technologies COATEMA Coating Machinery GmbH 19

20 Printed Electronic processes Products / Processes Common points for printed Electronics are High volume and large area device Lateral and vertical resolution requirements But different applications have different requirements! OPV large area, multilayer film low thickness tolerance high uniformity OTFT High lateral resolution, small feature size high density integration COATEMA Coating Machinery GmbH 20

21 Technologies & Processes From Lab2Fab COATEMA Coating Machinery GmbH 21

22 Scaling up new technologies Scaling up Flexibility Precision Bespoken Near to market Products Enabling Standardized COATEMA Coating Machinery GmbH 22

23 Overview on OPV Efficiency reached today COATEMA Coating Machinery GmbH 23

24 Overview on OPV Inverted structure for OPV Preferred architecture for R2R manufacturing Hole Transport Encapsulation Layer nm Anode 50nm-10µm Hole Transport Layer nm Photoactive Layer nm Cathode Transparent Electrode 50nm-1µm Substrate Glass or barrier film Solution-processed metals (such as Silver) Solution-processed ZnOx Transparent ITO or metal oxides Plastic film (i.e. PET, PEN) Conductive solution with Conductive polymer Matrix material Additives Co-solvents Bulk heterojunction with Polymer p-type (P3HT) Fullerene n-type (C60 PCBM) Aromatic solvents COATEMA Coating Machinery GmbH 24

25 Overview on OPV Production chain for modules Treatment of films Diode setting and soldering Adhesive apllication on films Solvent or waterbased coating lines Bus bar application lines Encapsulation lines Printing Technologies Laminators for packaging/encapsulation QM-Systems Dryers and annealing ovens ITO/Pedot/TiO2/Dye apllication systems Module to substrate bonding It is not only printing or coating to reach efficiency record modules! COATEMA Coating Machinery GmbH 25

26 Scaling up new technologies Tools for Lab2Fab COATEMA Coating Machinery GmbH 26

27 Lab, Pilot and production tools Test Solution With Slot Die COATEMA Coating Machinery GmbH 27

28 Lab, Pilot and production tools Test Solution R2R COATEMA Coating Machinery GmbH 28

29 Lab, Pilot and production tools The Easycoater COATEMA Coating Machinery GmbH 29

30 Lab, Pilot and production tools The Thin Film Coater & Printer COATEMA Coating Machinery GmbH 30

31 Lab, Pilot and production tools The Smartcoater COATEMA Coating Machinery GmbH 31

32 Lab, Pilot and production tools The Basecoater 3rd Generation COATEMA Coating Machinery GmbH 32

33 Lab, Pilot and production tools The Click&Coat COATEMA Coating Machinery GmbH 33

34 Upscaling from Lab2Fab Going to Fab - Technologies COATEMA Coating Machinery GmbH 34

35 Scaling up new technologies Production lines COATEMA Coating Machinery GmbH 35

36 Scaling up new technologies The key The right fit, regarding production speed, accuracy, resolution, capital investment and cost of ownership determines the market success of a production value chain for large area printed electronics. And a market for the products! COATEMA Coating Machinery GmbH 36

37 Proof of concept COATEMA Coating Machinery GmbH 37

38 Technologies & Processes Overview and Basics Surface treatment Printing Coating Nanoimprinting Photolithography Laser Patterning Pick & place Encapsulation COATEMA Coating Machinery GmbH 38

39 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 COATEMA Coating Machinery GmbH 39

40 Technologies & Processes Inline Process Integration Tension control load cell dancer pulling devices design of drives Quality control Edge guide control different sensors mechanical stress Registration control camera fiber optic design of drives Process analysis particle contamination analysis defect detection thickness control function control of the device or layer Statistic parameters product flow analysis Yield Cost of ownership COATEMA Coating Machinery GmbH 40

41 Web paths in Regac Technologies & Processes Inline process control COATEMA Coating Machinery GmbH 41

42 Technologies & Processes Inline Process Integration COATEMA Coating Machinery GmbH 42

43 Technologies & Processes Inline Process Integration Unwinder Slot Die 3m Dryers ps Laser Rotary coating screen printing Measuring Controlling Ink Jet 3m Dryers ns Laser In-line Cooling Optical Metrology (SE, Raman) Rewinder COATEMA Coating Machinery GmbH 43

44 Technologies & Processes Inline Process Integration COATEMA Coating Machinery GmbH 44

45 Technologies & Processes Winding / Cleaning Unwinding cabinet Can receive rolls with core of 3 inch. Max diameter of 500 mm Max weight 50 kg Web width of 300 mm Automated forward and reverse movement of the web Speed of 1-20 m/min Tension control of the web within the range of N. Web Cleaning system Contact cleaning rollers for particles of >1μm diameter COATEMA Coating Machinery GmbH 45

46 Technologies & Processes Inline Process Integration 1 st Printing Web surface activation with Plasma Treatment Dryer 1 3 meter Dryers Hot air and heated nitrogen Temperatures up to 230 C COATEMA Coating Machinery GmbH 46

47 Technologies & Processes Slot die coating Slot-die coating station compatible for materials used in OEs Print solutions with viscosity range of mpa s The above range can lead to layer thickness range of nm Lateral accuracy of ±1% COATEMA Coating Machinery GmbH 47

48 Technologies & Processes Inline Process Integration manifold + meniscus guide meniscus + shim + guide = improved edges Coatema Meniscus Guide COATEMA Coating Machinery GmbH 48

49 Technologies & Processes Laser Patterning Laser Scribing/Patterning Picosecond laser for patterning OE materials 3 meters cabinets Tension and driving web control system ±100 μm of accuracy COATEMA Coating Machinery GmbH 49

50 Technologies & Processes Rotary screen printing 2 nd Printing Station Rotary screen printing Coating width of 300mm Lateral accuracy ±5%. Dryer 2 3 meters Dryers Hot air and heated nitrogen Temperatures up to 230 C COATEMA Coating Machinery GmbH 50

51 Technologies & Processes Inline Process Integration Inkjet station Inkjet station Trident System Coatema Software Already integrated: Fuji Dimatix Xaar COATEMA Coating Machinery GmbH 51

52 Technologies & Processes Module for the registration Camera Technical Specifications: Measurement Accuracy = +/-5 µm (t.b.d.) ATEX proof 300 mm roller width Web speed: 1-20 m/min; Optimum speed is 3-20 m/min PLC-driven correction adjustment system Module to be operated under N COATEMA Coating Machinery GmbH 52

53 Technologies & Processes Encapsulation Rewinding station The rewinding station has a retaining roller Identical specs to the unwinding station 3 inch core rolls. Automated forward and reverse movement of the web Speed of 1-20 m/min Tension control and Edge guide system Lamination/delamination station Compatible with 300mm web width. Web Control with Edge guide system Lateral accuracy of ±100 μm / 20 µm COATEMA Coating Machinery GmbH 53

54 Inline Quality control Technologies & Processes Ellipsiometry and inline Raman by Horiba COATEMA Coating Machinery GmbH 54

55 Technologies & Processes Summary 19 m in length 300 mm working width 30m/min per minutes production speed 3 print stations Plasma treatment mm nitrogen dryers in 500 mm sections Registration control Laminating station COATEMA Coating Machinery GmbH 55

56 Technologies & Processes Summary 19 m in length 300 mm working width 30m/min per minutes production speed 3 print stations Plasma treatment mm nitrogen dryers in 500 mm sections Registration control Laminating station COATEMA Coating Machinery GmbH 56

57 Technologies & Processes From Lab2Fab COATEMA Coating Machinery GmbH 57

58 Technologies & Processes Printocent Pilot Factory 1.0 Best Technical Development Manufacturing Awards 2012 Berlin, 2012 Santa Clara, 2013 Berlin, 2013 Tokyo COATEMA Coating Machinery GmbH 58

59 Technologies & Processes Printocent Pilot Factory COATEMA Coating Machinery GmbH 59

60 Technologies & Processes Printocent Pilot Factory 1.0 Facts 4 interchangeable printing unit slots forward gravure reverse gravure rotary silk screen Flexography slot die coating Hot embossing unit Plasma substrate treatment unit Lamination unit Rotary die cut unit Drying units (air, UV) Automatic registration system Max. web width 300mm Max. web velocity 30m/min COATEMA Coating Machinery GmbH 60

61 Technologies & Processes Coating Systems COATEMA Coating Machinery GmbH 61

62 Coating systems Coatema s coating systems Knife Double Side Commabar Case Knife Slot Die Hotmelt Slot Die Engraved Roller Powder Scattering 3 Roller Combi Micro Roller 5 Roller Reverse Roll Double Knife Curtain Coating 2 Roller Combi Dipping Rotary Screen >30 application systems COATEMA Coating Machinery GmbH 62

63 Technologies & Processes Coating Parameters Coating Chemistry Coating Processes Process control Drying Rheology Viscosity Viscoleasticity Type of solvents Amount of solids Van der Waals force Sheer ratio Adhesion/Cohesion Coating systems Single or Multilayer coatings Direct coatings Transfer (indirect) coatings Substrate speed Layer Thickness Coating accuracy Process layout Tension control system Material guiding system Inline parameter control Quality control Convection drying Contact drying Infrared drying Sintering NIR High Frequency UV crosslinking systems Substrate Pretreatment Environment Finishing Surface tension Dimension stability Surface structure Contact angle Corona Plasma Cleaning Humidity Temperature Inert Conditions Calendaring Embossing Slitting COATEMA Coating Machinery GmbH 63

64 Coating systems Coatema s coating systems Example Characteristics Self - metered Wet thickness is determined by the conditions of coating meniscus Doctored Post applicator device determines the wet thickness Pre - metered All ink fed into an applicator is transferred to the web COATEMA Coating Machinery GmbH 64

65 Technologies & Processes Slot Die System COATEMA Coating Machinery GmbH 65

66 Technologies & Processes Slot Die System Slot Die Coating Parameters Printing Speed Ink viscosity m/min 0, Pa s Layer Thickness 0,2-200 µm Coating accuracy 1-5 % COATEMA Coating Machinery GmbH 66

67 Technologies & Processes Slot Die System OPV slot die High precision slot die Meniscus mode COATEMA Coating Machinery GmbH 67

68 Technologies & Processes Slot Die System Operating a 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 Slot die Distribution chamber meniscus Coating roller COATEMA Coating Machinery GmbH 68

69 Technologies Slot Die System Slot Die Coating capillary stripe widening shim fluid Slot Die with manifold typical distance 100µ or less moving substrate or COATEMA Coating Machinery GmbH 69

70 Technologies & Processes Slot Die System Manifold + Shim + Meniscus guide = stripe stabilization by meniscus guide COATEMA Coating Machinery GmbH 70

71 Technologies & Processes Printing Systems COATEMA Coating Machinery GmbH 71

72 Technologies & Processes Printing Systems Gravure printing Flexo printing Screen printing COATEMA Coating Machinery GmbH 72

73 Technologies & Processes Printing Parameters COATEMA Coating Machinery GmbH 73

74 Technologies & Processes Printing Parameters Printing method Printing Nip Ink Layer Feature Regis- speed pressure viscosity thickness size tration (m/s) (MPa) (Pa s) (µm) (µm) (µm) Flexography ,1 0,5 0,01 0,5 0, Gravure ,5 5 0,01 0,2 0, >10 Offset , , >10 Screen printing 2-0, >25 Inkjet 1 5-0,001 0,03 0,01-0,5, 20 (UV) < COATEMA Coating Machinery GmbH 74

75 Technologies & Processes Printing Systems Gravure printing Flexo printing Screen printing COATEMA Coating Machinery GmbH 75

76 Technologies & Processes Gravure Printing Gravure Printing Parameters Printing Speed m/s Nip Pressure 1,5-5 MPa Ink viscosity 0,01-0,2 Pa s Layer Thickness 0,04-12 µm Feature Size µm Resolution µm COATEMA Coating Machinery GmbH 76

77 Technologies & Processes Flexo Printing Flexo Printing Parameters Printing Speed Nip Pressure Ink viscosity 3 10 m/s 0,1 0,5 MPa 0,01-0,5 Pa s Layer Thickness 0,1-12 µm Feature Size µm Resolution µm COATEMA Coating Machinery GmbH 77

78 Technologies & Processes Screen Printing Screen Printing Parameters Printing Speed 2m/s Nip Pressure Ink viscosity 0,1-50 Pa s Layer Thickness µm Feature Size µm Resolution µm COATEMA Coating Machinery GmbH 78

79 Technologies & Processes Inkjet Printing COATEMA Coating Machinery GmbH 79

80 Technologies & Processes Registration Control system COATEMA Coating Machinery GmbH 80

81 Technologies & Processes Registration control system COATEMA Coating Machinery GmbH 81

82 Technologies & Processes Dimension of Registration marks COATEMA Coating Machinery GmbH 82

83 TD error Technologies & Processes Registration Background er MD TD Definition of the register error 1 st layer 2 nd layer Desired position 2 nd Printed position layer 1 st print 2 nd print Ref : IEEE trans. On electron devices, Vol 57, No. 3, Mar Register error - is defined as error in printing position on the multi-layer printing process - has 2 directions: Cross-direction (CD) and machine-direction (MD) - is affecting the performance of the printed electronics - is important for increasing the density of array of printed electronics - should be minimized within printing tolerance MD error COATEMA Coating Machinery GmbH 83

84 Technologies & Processes Registration control loop R2R printing process registration accuracy is affected by COATEMA Coating Machinery GmbH 84

85 Web paths in Regac Technologies & Processes Registration case study COATEMA Coating Machinery GmbH 85

86 How to increasing of printing accuracy Technologies & Processes Registration control system Speed synchronization Check - speed control loop - tension control loop Check - exact shape of the pattern - location accuracy of the pattern Tension control Register control Machining precision Check - machining precision - location of the load cell Check - camera sensing resolution - sensing algorithm COATEMA Coating Machinery GmbH 86

87 Technologies & Processes Offcode s Coatema joined development COATEMA Coating Machinery GmbH 87

88 Technologies & Processes Specifications Detector: Register marks printed on Polymer film, μm, z.b. PET, PC Register marks printed on various metal films, μm, z.b. copper, Alu Register marks printed using opaque ink, e.g. silver, phosphor, dielectric Register marks printed using transparent ink, e.g. transparent conductive ink Interface to existing coat & click line by voltage interface Adjustment speed: at least 0,4 mm/s Adjustment range: at least +/- 5 mm Remote control possible, setup management, user management, password management, recipe management Polling rate: 1 data per second Communication port: Ethernet, RS-485, modbus TCP/IP Communication speed: 9600 bps Software shall be extensible and upgradeable Explosion proof features of the units inside the printing cell COATEMA Coating Machinery GmbH 88

89 Technologies & Processes C&C Module for the registration Camera Technical Specifications: Measurement Accuracy = +/-5 µm (t.b.d.) ATEX proof 300 mm roller width Web speed: 1-20 m/min; Optimum speed is 3-10 m/min PLC-driven correction adjustment system Module to be operated under N COATEMA Coating Machinery GmbH 89

90 Technologies & Processes Production scale integration COATEMA Coating Machinery GmbH 90

91 Technologies & Processes Prototyping in real scale Test with registration marks to proof principle Happy Engineer = promising results! COATEMA Coating Machinery GmbH 91

92 Technologies & Processes C&C Module for the registration Camera COATEMA Coating Machinery GmbH 92

93 Technologies & Processes Scribing/Patterning Systems COATEMA Coating Machinery GmbH 93

94 Technologies & Processes Objectives Roll-to-roll system with integrated laser processes for manufacturing of organic solar cells Industry-ready laser processes: monolithic series interconnection, edge deletion, encapsulation Organic solar cells from laser-based process chain with 3% conversion efficiency Web speed of up to 10 m/min, laser structuring of thin films with > 10 m/s COATEMA Coating Machinery GmbH 94

95 Technologies & Processes Innovations Cost-efficient roll-to-roll production technology by integration of laser processes Application of high power ultra-short pulse lasers for residue-free ablation without material modification Demonstration system with integrated process chain (Coating, drying, laser structuring) Potential for other applications of organic electronics (RIFD tags, printed electronics, OLED lighting) COATEMA Coating Machinery GmbH 95

96 Technologies & Processes Innovations Patterning 1 Insulation Step ZnO-NP ITO PET Patterning 2 Contacting Step PEDOT:PSS P3HT:PCBM PET Patterning 3 Insulation Step Silver PEDOT:PSS P3HT:PCBM PET COATEMA Coating Machinery GmbH 96

97 Technologies & Processes Innovations Patterning 1 Insulation Step ZnO-NP ITO PET Patterning 2 Contacting Step PEDOT:PSS P3HT:PCBM PET Patterning 3 Insulation Step Silver PEDOT:PSS P3HT:PCBM PET COATEMA Coating Machinery GmbH 97

98 Technologies & Processes Innovations Patterning 1 Insulation Step ZnO-NP ITO PET Patterning 2 Contacting Step PEDOT:PSS P3HT:PCBM PET Patterning 3 Insulation Step Silver PEDOT:PSS P3HT:PCBM PET COATEMA Coating Machinery GmbH 98

99 Technologies & Processes Flexlas Demonstrator Coater IR dryer Space for integration of laser processes Inertized housing Coatema ILT RUB 4Jet LIMO Smartcoater system Process integration Process development Process control Optical system COATEMA Coating Machinery GmbH 99

100 Technologies & Processes Integration of laser processes Process control: web edge and scribe detection Structuring: eleven scribes simultaneously for high througput Edge deletion: galvo scanner for flexibility Encapsulation: gap and transmission welding of polymer substrates with barrier function (not shown) COATEMA Coating Machinery GmbH 100

101 Technologies & Processes Integration of laser processes COATEMA Coating Machinery GmbH 101

102 Integration of laser processes Technologies & Processes COATEMA Coating Machinery GmbH 102

103 Technologies & Processes Laser Technology in Roll-to-Roll Thin Film Processes COATEMA Coating Machinery GmbH 103

104 Technologies & Processes Laser Technology in Roll-to-Roll Thin Film Processes COATEMA Coating Machinery GmbH 104

105 Technologies & Processes Nanoimprint Lithography COATEMA Coating Machinery GmbH 105

106 Technologies & Processes Nanoimprint Lithography A B Nanoparticle solution C PDMS mold SiO2 Highly doped Si wafer SiO2 Highly doped Si wafer SiO2 Highly doped Si wafer D 5 Psi E F PDMS mold Dried nanoparticles Gold SiO2 Highly doped Si wafer 80 C SiO2 Highly doped Si wafer SiO2 Highly doped Si wafer 140 C COATEMA Coating Machinery GmbH 106

107 Hard mold Soft mold Ultra Violet NIL Thermal NIL Technologies & Processes NIL Nano imprint lithography R2R roll-to-roll R2P roll-to-plate P2P plate-to-plate UV-curable lacquer/ resin short process time processing at room temperature Hard or soft molds Low imprint pressure High replication resolution Low material shrinkage Thermoplastic substrate/ resin Long process time processing above T G Hard molds High imprint pressure one-component system High material shrinkage + wear behaviour + imprint pressure + life time of replication mold + life time of master mold + resolution + flexibilty COATEMA Coating Machinery GmbH 107

108 Technologies & Processes Aspect ratio (AR) 5.4:1 (h:w) (ETFE mold, UV R2R NIL) [1] Residual layer (RL) thickness 30 nm [2] Coating thickness 160 nm [2] 150 µm [3] Film speed 15m/min [4] Resolution 70 nm (gratings of 70-nm lines) [4] [1] Ahn, B.S.H.; Guo, L.J.: High-Speed Roll-to-Roll Nanoimprint Lithography on Flexible Plastic Substrates. In: Advanced Materials. vol , p [2] Mäkelä, T.; Haatainen, T.; Majander, P.; Ahopelto, J.: Continuous roll to roll nanoimprinting of inherently conducting polyaniline. In: Microelectronic Engineering. vol. 84, 2007, p [3] Shan, X.C.; Lau, S.K.; Mohahidin, M.B.; Liu, T.; Lu, A.C.W.: Formation of Large Format Functional Films via Roll-to-Roll (R2R) Ultraviolet (UV) Embossing. In: IEEE Proc. of 13th Electronics Packinging Technology Conference [4] Kooy, N.; Mohamed, K.; Pin, L.T.; Guan, O.S.: A review of roll-to-roll nanoimprint lithography. In: Nanoscale Research Letters. vol. 9:320, COATEMA Coating Machinery GmbH 108

109 Technologies & Processes Nanoimprinting Combi System Nanoimprint UV lithography Thermal Nanoimprint COATEMA Coating Machinery GmbH 109

110 Technologies & Processes Nanoimprinting System Protective film Coating unit Unwinding Alignment UVNIL Rewinding COATEMA Coating Machinery GmbH 110

111 Technologies & Processes Nanoimprinting System COATEMA Coating Machinery GmbH 111

112 Technologies & Processes Nanoimprinting System COATEMA Coating Machinery GmbH 112

113 Technologies & Processes Nanoimprinting System COATEMA Coating Machinery GmbH 113

114 Technologies & Processes Nanoimprint Lithography COATEMA Coating Machinery GmbH 114

115 Technologies & Processes Nanoimprint Lithography COATEMA Coating Machinery GmbH 115

116 Technologies & Processes Nanoimprint Lithography COATEMA Coating Machinery GmbH 116

117 Technologies & Processes Nanoimprint Lithography COATEMA Coating Machinery GmbH 117

118 Technologies & Processes Nanoimprint Lithography COATEMA Coating Machinery GmbH 118

119 Technologies & Processes Thermal NIL Hot embossing Parameters Printing Speed 0,1-3 m/min Nip Pressure Register controlled COATEMA Coating Machinery GmbH 119

120 Technologies & Processes Rollers for Nanoimprinting Soft-Nanoimprint Drum COATEMA Coating Machinery GmbH 120

121 Technologies & Processes European project ML2 Project consortium: COATEMA Coating Machinery GmbH 121

122 Technologies & Processes Nanoimprint Lithography Demonstrator 1: Pathogen diagnostic lab-on-a-chip Detection platform for flexible detection of target DNA (e.g. bacteria DNA) Continuous flow polymerase-chain reaction (PCR) Mixing of DNA with the appropriate PCR reagents Amplification of target DNA by rapid thermal cycling Amplicon detection -> Reagents must be adapted in terms of types, concentration and mixture for certain targets Example Protocol Reaction mixtur 167 µl HotStar Master Mix 16.7 µl Taqman Custom Assay 10 µl PEG μl H2O 3.3 μl 3% BSA 200 μl TOTAL On-Chip Mix 150 μl Reaction Mixture 37.5 μl B. subtilis genomic DNA (0.24 µg/ml) 62.5 μl H2O 250 μl TOTAL Rapid thermal cycling: Heater 1: 95.5 C, Heater 2: 60 C Automated Protokoll: PCR takes 15 minutes Prototype Multi-Layering COATEMA Coating Machinery GmbH 122

123 Technologies & Processes Slot-die coating unit Substrate specifications Structured drum Imprint unit Transparent polymer substrats (e.g. PET, PMMA, PC, COC) microns thickness 500 mm max. substrate width Lacquer specifications Arcylic based Deep blue, UV-A/B activated mpa s COATEMA Coating Machinery GmbH 123

124 Technologies & Processes 1. Top sealing layer 2. Optical layer light guide for fluorescence detection 3. Microfluidic layer Fluid input, mixer, serpentine channel, detection well 4. Electrical layer Heaters for two temperature zones 5. Bottom sealing layer Polymer substrate Bonding layer Vertical combination of functional layers Source: Fraunhofer CMI, European Comminssion Sealed microfluidic channels Structured UV-Lacquer Polymer substrate COATEMA Coating Machinery GmbH 124

125 ML 2 MultiLayer Microlab Technologies & Processes Low-cost R2R production of smart multi functional 3Dcomponents by layered devices Project duration: Sept Aug PCR chip design study Functional Demonstrators Diagnostic Lab-on-a-chip Principle: Polymerase chain reaction chip Water analysis Principle: Immunoassay using fluorescence detection Point-of-care-diagnostic Principle: Lateral-Flow-Test using magnetic particles as marker Project consortium: Source: Fraunhofer CMI, European Commission COATEMA Coating Machinery GmbH 125

126 Upscaling from Lab2Fab Technologies COATEMA Coating Machinery GmbH 126

127 Scaling up new technologies The key COATEMA Coating Machinery GmbH 127

128 Scaling up new technologies The key COATEMA Coating Machinery GmbH 128

129 Scaling up new technologies The key COATEMA Coating Machinery GmbH 129

130 Scaling up new technologies The key COATEMA Coating Machinery GmbH 130

131 Upscaling from Lab2Fab Going to Fab - Technologies Enhanced Energy Efficiency and Comfort by Smart Light Transmittance Control A FP 7 research project coordinated by The EELICON project receives funding from the European Union s Seventh Framework Programme (FP7) - THEME NMP From research to innovation: substantial steps forward in the industrial use of European intellectual assets, stimulating the use of newly developed materials and materials technologies by the industry - under grant agreement n Duration: COATEMA Coating Machinery GmbH 131

132 Upscaling from Lab2Fab Going to Fab - Technologies * TT TT Technology transfer COATEMA Coating Machinery GmbH 132

133 Upscaling from Lab2Fab Going to Fab - Technologies COC Ltd COATEMA Coating Machinery GmbH 133

134 Upscaling from Lab2Fab Going to Fab - Technologies Reference: private property EControl-Glas GmbH Reference: Fraunhofer IST, Braunschweig darkened bleached EControl-Glas GmbH EControl-Glas GmbH EControl-Glas GmbH With kind permission of Econtrol-GlasGmbH & Co. KG COATEMA Coating Machinery GmbH 134

135 Bright state Dark state Upscaling from Lab2Fab Going to Fab - Technologies Obscuring sight Enhancing comfort Improving energy efficiency Protecting from sunlight and glare Individual layout of work place environments EControl-Glas GmbH COATEMA Coating Machinery GmbH 135

136 Upscaling from Lab2Fab Going to Fab - Technologies The result - Stand-alone EC film Fraunhofer ISC Fraunhofer ISC Bright state * Manually assembled lab prototype * High bright state transmittance ( v = %) COATEMA Coating Machinery GmbH 136

137 Upscaling from Lab2Fab Going to Fab - Technologies Fraunhofer ISC The result - Stand-alone EC film Dark state Fraunhofer ISC Fraunhofer ISC Response time s Low dark state transmittance ( v = 5-10 %) >100k cycles under lab conditions COATEMA Coating Machinery GmbH 137

138 Upscaling from Lab2Fab Going to Fab - Technologies Desired property profile mechanical flexibility low weight high safety retrofitting possibility simple process energy-efficient & cost-effective high-throughput production Application example from former project INNOSHADE EADS COATEMA Coating Machinery GmbH 138

139 Upscaling from Lab2Fab Going to Fab - Technologies No blue hue in bright state Virtually colourless, like reference without active films CIE L*a*b* Colour coordinates Device without polymer (dummy) Device with new polymer The solution - Patented EC polymers... Groupe NH photographers for HQ COATEMA Coating Machinery GmbH 139

140 Upscaling from Lab2Fab Going to Fab - Technologies Roll-to-roll processes In-Situ-Coating polymerisation Pre- & post-treatments Scaled to 500 mm Process automation Fraunhofer ISC COATEMA Coating Machinery GmbH 140

141 Upscaling from Lab2Fab Going to Fab - Technologies COATEMA Coating Machinery GmbH 141

142 Upscaling from Lab2Fab Going to Fab - Technologies Preparation of electrodes ( half-cells ) COATEMA Coating Machinery GmbH 142

143 Upscaling from Lab2Fab Going to Fab - Technologies Preparation of electrodes ( half-cells ) Fraunhofer ISC Fraunhofer ISC Fraunhofer ISC COATEMA Coating Machinery GmbH 143

144 Upscaling from Lab2Fab Going to Fab - Technologies polymer electrolyte application UV curing Fraunhofer ISC Fraunhofer ISC COATEMA Coating Machinery GmbH 144

145 Upscaling from Lab2Fab Going to Fab - Technologies CE half-cell lamination Electrolyte EC Polymer half-cell Fraunhofer ISC COATEMA Coating Machinery GmbH 145

146 Upscaling from Lab2Fab Going to Fab - Technologies Fraunhofer ISC Fraunhofer ISC Fraunhofer ISC COATEMA Coating Machinery GmbH 146

147 Upscaling from Lab2Fab Summary COATEMA Coating Machinery GmbH 147

148 Upscaling from Lab2Fab Going to Fab Needed for success: Reproducible results in every step of scale? Reality check if the approach is really scalable? Is the approach an approach for the real life production environment or is it rocket science? Are economies of scale reachable and when? Are there existing production technologies which could be used for a benchmark analysis? COATEMA Coating Machinery GmbH 148

149 COATEMA Coating Machinery GmbH THANK YOU Roseller Str. 4 D Dormagen / tkolbusch@coatema.de COATEMA Coating Machinery GmbH 149

150 COATEMA Coating Machinery GmbH 150

151 Technologies & Processes Slot Die System COATEMA Coating Machinery GmbH 151

152 Technologies & Processes Slot Die System Operating a 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 Slot die Distribution chamber meniscus Coating roller COATEMA Coating Machinery GmbH 152

153 Basics of slot die coating Characteristic features homogeneous, thin layers dosing (metering) system touchfree (except in impregnation mode) closed system (no evaporation of solvents) full area non stop coating patterned and start-stop coatings The slot die is the only system, that combines all these features COATEMA Coating Machinery GmbH 153

154 Basics of slot die coating Range of coating parameters Printing Speed (m/min) >1000 Ink viscosity (mpa s) Layer Thickness 0,1 - >200µm Coating accuracy <1% Coating width up to approx. 3 m COATEMA Coating Machinery GmbH 154

155 Basics of slot die coating Slot Die examples 100 mm 11 o clock 500 mm slightly tilted 300 mm 9 o clock 300 mm double sided COATEMA Coating Machinery GmbH 155

156 Basics of slot die coating Coatema standard layout lips slot area manifold COATEMA Coating Machinery GmbH 156

157 Basics of slot die coating Coatema standard layout The shim as spacer determines the coating width and slot width shim coating width COATEMA Coating Machinery GmbH 157

158 Basics of slot die coating Operating modes of a slot die Bead mode 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 preferrably for low coating speed Slot die Coating roller Manifold (Distribution chamber) Meniscus COATEMA Coating Machinery GmbH 158

159 Basics of slot die coating Operating modes of a slot die Curtain mode Freely falling liquid curtain No adhesive stabilization of wetting line by die lips Curtain width shrinks while falling Minimum flow rate necessary for stable curtain Preferrable for high coating speed Slot die Coating roller Manifold (Distribution chamber) Freely falling liquid curtain Coating roller COATEMA Coating Machinery GmbH 159

160 Basics of slot die coating Operating modes of a slot die Impregnation mode slot die acts as an impregnator with defined liquid release sucking strength of web must be smaller than release strength of the slot die slot die with high retention ability has to be used preferrably for low porosity nonwovens COATEMA Coating Machinery GmbH 160

161 Basics of slot die coating Pros and cons of slot die coating Advantages: - completely closed system - no change of solid concentration by evaporation - no hazardous vapors - metering system coating thickness depends on pump, width and speed only Disadvantages: - relatively complex and sensitive - works only with adequate rheology - has to be treated with care (cleaning, no scratches) - expensive (depending on complexity) V p = v B x - very low layer thicknesses possible by dilution COATEMA Coating Machinery GmbH 161

162 Homogeneous coating with slot dies COATEMA Coating Machinery GmbH 162

163 Homogeneous Coating Target of homogeneity Web direction The target in thickness profile depends on application. E.g. window foils: target is determined by sensitivity of human eye - standard optical density for window foils in dark state: D = (absorption 75-80%) - in this range the human eye detects density variations of: ΔD = (depending on the regularity of the variations) - density is proportional to layer thickness: I = I ax D = - log I/I 0 = ax ΔD / D = Δx / x target of layer homogeneity: % COATEMA Coating Machinery GmbH 163

164 Homogeneous Coating Theoretical thickness profile Theoretical thickness profile of a slot die Condition for good profile: Δp3 «Δp COATEMA Coating Machinery GmbH 164

165 Homogeneous Coating How to improve the coating profile large manifold T die, long slot area (standard design) coat hanger design - profile is compensated by a tilted manifold - manifold cross section shrinks to keep flow speed constant (optional to prevent precipitation) - works perfect for adequate rheology only slot width adjustment - slot width is locally narrowed or widened to adjust the local flow resistence - the slot width can be modified by microns only, so despite the adjustability the die has nevertheless to be highly precise and a big manifold is necessary. (The adjustment is a fine tuning only.) COATEMA Coating Machinery GmbH 165

166 Homogeneous Coating Slot die mathematics dv p /dt = B v x Δp = 12 η l V p D 3 B D = 3 12 η l V p Δp B COATEMA Coating Machinery GmbH 166

167 Slot die mathematics ρ v da = 0 Continuity equation (conservation of mass) Any flow of liquids is described by a set of differential equations: To describe the meniscus flow of a slot die means, to solve these differential equations for given boundary conditions. Can be done by appropriate computer programs. v t + (v )v = {- p + η Δv + f } / ρ Navier-Stokes-equations (equations of motion for incompressible fluids, ρ=const), Δ = differential operators But for practical applications, some important parameters can be estimated by analytical calculations COATEMA Coating Machinery GmbH 167

168 Slot die mathematics Calculation of coating thickness Shim thickness dv p /dt = B v x Distance to substrate Coating thickness wet Coating speed Coating width Flow rate of the pump Coating roller Contrary to a widespread misunderstanding the wet coating thickness does not depend on the shim thickness. Shim thickness and distance to substrate only help to stabilize the meniscus COATEMA Coating Machinery GmbH 168

169 Slot die mathematics Calculation of internal pressure Slot Die Mathematics: Manifold Pressure dependent on Shim Thickness and Viscosity Δp = 12 η l V p D 3 B manifold pressure (Pa) shim thickness (µ) viscosity (mpas) Vp = 22 ml/min B = 400 mm l = 28 mm COATEMA Coating Machinery GmbH 169

170 Slot die mathematics Calculation of shim thickness Slot Die Mathematics: Shim Thickness dependent on Viscosity and Volume Flow 600 D = 3 12 η l V p Δp B shim thickness (µ) volume flow (ml/min) viscosity (mpas) Δp = Pa B = 400 mm l = 28 mm COATEMA Coating Machinery GmbH 170

171 Slot die mathematics Calculation of shear force slot width w coating width B y coating gap d lip width b Shear force F s coating thickness h x web speed v Force caused by shear: This force pulls the meniscus to the right. A d v COATEMA Coating Machinery GmbH 171

172 Slot die mathematics Calculation of surface tension force y x slot width w coating gap d lip width b coating width B surface tension force F t coating thickness h web speed v Force caused by surface tension: This force pulls the meniscus to the left COATEMA Coating Machinery GmbH 172

173 Slot die mathematics Calculation of vacuum force reduced pressure Δp slot width w coating width B vacuum force F v coating gap d lip width b coating thickness h y web speed v x Force caused by reduced pressure on the rear of the meniscus: This force pulls the meniscus to the left COATEMA Coating Machinery GmbH 173

174 Slot die mathematics Estimation of coating speed y x slot width w coating gap d lip width b coating width B F s = F v + F t coating thickness h web speed v Stability of the meniscus: The meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces. At maximum speed the forces are equal. From this you get a rough estimation of maximum speed COATEMA Coating Machinery GmbH 174

175 Homogeneous Coating T Design- slot die COATEMA Coating Machinery GmbH 175

176 Homogeneous Coating Coat hanger slot die manifold small to minimize dead volume (optional conical to prevent precipitation) tilted manifold to correct the pressure profile long slot area COATEMA Coating Machinery GmbH 176

177 Homogeneous Coating Slot die with slot width adjustment slot (shim edge) differential adjustment screws space for bending the die lip COATEMA Coating Machinery GmbH 177

178 Homogeneous Coating Typical menisci for coating meniscus on full width meniscus on reduced width (limited by shim) COATEMA Coating Machinery GmbH 178

179 Homogeneous Coating Typical coating profiles perfect thickness profile bad thickness profile COATEMA Coating Machinery GmbH 179

180 Structured coating with slot dies COATEMA Coating Machinery GmbH 180

181 Structured coating Levels of complexity Web direction level of complexity current status 1 full area, homogeneous requirements are met, thickness profile variation of 0.5 % 2 stripes downweb, (edges downweb) requirements met, good edge definition 3 stripes crossweb, (intermittent coating, edges crossweb) edge definition of mm depending on liquid abc 4 arbitrary patterns requirements are not met, concepts for realization exist, COATEMA Coating Machinery GmbH 181

182 Structured coating Material direction stripes downweb stripes of different width are made by appropriate shims COATEMA Coating Machinery GmbH 182

183 Structured coating MD stripes, flow details shim fluid fluid 100µ typ. moving substrate or Problem: Stripe width and gap width may be affected by capillary forces at the edges of the shim teeth. capillary forces widen the stripes COATEMA Coating Machinery GmbH 183

184 Structured coating MD stripes suppression of stripe widening by meniscus guide manifold shim meniscus guide + + = well defined stripes COATEMA Coating Machinery GmbH 184

185 Structured coating MD stripes shim and meniscus guide meniscus guide shim meniscus guide + shim COATEMA Coating Machinery GmbH 185

186 Structured coating Slot die qualification - wavyness a) Wavyness of a straight downweb edge The wavyness of a straight coating edge was measured: with an optical microscope using samples made during the previous trials and with the Raman camera using actual samples made during the current trials. The target of ±5µ was fulfilled in both cases. The following 2 slides show pictures of the measurement results COATEMA Coating Machinery GmbH 186

187 Structured coating Slot die qualification, wavyness Stripes coated , pictures taken by optical microscope The bright line is the slightly wavy coating edge. The dotted rectangle depicts a width of 10µ = ±5µ. The wavyness is clearly smaller COATEMA Coating Machinery GmbH 187

188 Structured coating Slot die qualification, wavyness coated uncoated 10µ Local peak is not caused by slot die Actual coating, picture is taken by the Raman camera. Again the wavyness is smaller than 10µ = ±5µ COATEMA Coating Machinery GmbH 188

189 Structured coating Slot die qualification, stripe width PVOH Results and data handling: Stripe width variation is affected not only by the slot die but as well by the rheology and surface energy of the liquid and the substrate. That is, why it is justified to use test ink with known rheology in order to minimize any strange influences, which affect the result but do not have to do anything with the slot die. An example of such strange influences are particles, which might stick to the edges of the meniscus guide teeth and thereby affect the stripe width. Therefore in order to draw the most reliable conclusion out of a series of measurements it is a well known good practice, to exclude any outliers, usually max and min. This was done in the following data, whenever applicable COATEMA Coating Machinery GmbH 189

190 Structured coating Slot die qualification, stripe width PVOH Trial 2a, , coatema slot die, 0.5 m/min, y-axis enlarged overall variation +-20µ, skipping pink max/min-outliers +-5µ Coatema test die PVOH 0.5 m/min Result: +-5µ!! outliers skipped width (mm) 5,2 5,15 5,1 5,05 +-5µ stripe no COATEMA Coating Machinery GmbH 190

191 stripe width (mm) Structured coating Slot die qualification, stripe width PVOH PVOH 4 m/min Result: µ 12,1 12,05 12 ±5µ ±12.5µ skipping the outliers even gives +-5µ!! 11,95 11,9 11,85 11, stripe no COATEMA Coating Machinery GmbH 191

192 Structured coating Slot die qualification, stripe width PVOH For these trials Coatema developped a powerful tool for coating stripes of exact width with slot dies: the sandwich guide COATEMA Coating Machinery GmbH 192

193 Structured coating Crossweb stripes (intermittent coating) Slot die Manifold (Distribution chamber) Meniscus Intermittent coating requires sudden start /stop of the fluid flow. Different methods are available. Coating roller COATEMA Coating Machinery GmbH 193

194 Structured coating Intermittent coating techniques technique effectiveness 1 stop the pump very low: gives badly defined edges 2 reverse the pump (suck back) low: only slightly better than 1 3 reverse the pump (suck back) + lift the die 4 reverse the pump (suck back) + lift the die + suck or blow away the meniscus fair quite well: best achievable edge definition about mm 5 goal: 0.1 mm COATEMA Coating Machinery GmbH 194

195 Drying & Crosslinking COATEMA Coating Machinery GmbH 195

196 Technologies Drying Technologies Drying with hot air technology COATEMA Coating Machinery GmbH 196

197 Drying systems General tasks of drying Substrate Coating Heat transfer Vapor removal transfer drying energy into solids & solvent evaporate the solvent remove the solvent vapor dryer technology solid heat capacity solvent heat capacity solvent evaporation energy solvent evaporation speed dryer technology COATEMA Coating Machinery GmbH 197

198 Drying time Drying energy: Comparison of data The table summarizes relevant data of water and solvents. The data originate from different sources. No guarantee for correctness COATEMA Coating Machinery GmbH 198

199 Drying time Heat transfer An isolating air layer forms just on top of the coating layer. This layer is hardly moving and thereby hinders the heat transfer as well as the solvent evaporation. It has to be broken by sufficient air flow without sacrificing the coating surface. turbulent flow coating substrate laminar flow isolating air layer Usually there is a trade-off: effective fast heat transfer or gentle mild slow drying COATEMA Coating Machinery GmbH 199

200 Drying time Heat transfer coefficient The heat transfer coefficient α describes energy transfer from hot air to liquid Energy transfer Q can be calculated in fair approximation from Reynolds number Re, Prandtl number Pr and Nusselt number Nu: α = Q / { A (T D -T O ) } Re = wd/ν Pr = ν/a Nu = f (Re, Pr) An empirical function Nu = f (Re, Pr) is given in the literature for single slot nozzles and slot nozzle arrays. from Nu = α D / λ then derive α and Q COATEMA Coating Machinery GmbH 200

201 Drying time Overview on vapor pressure COATEMA Coating Machinery GmbH 201

202 Drying time Calculation of vapor pressure Vapor pressure can be calculated for any solvent at any temperature, if 2 pairs of pressure and temperature are known. Clausius-Clapeyron: log p = K 1 + K 2 / T Such pairs of p and T are available in the literature for any solvent. e.g. p (20 C) and T (1013 hpa) In the internet you find even autmated excel-sheets to calculate the vapor pressure for any solvent at any temperature from 2 pairs (p/t) COATEMA Coating Machinery GmbH 202

203 Drying time Calculation of evaporation rate Vapor pressure is one factor of evaporation rate, but not the only one. Other than for vapor pressure there is no simple way to calculate the evaporation rate for any solvent at the demanded temperature. Based on a modified Hertz-Knudsen approach, the evaporation rate of any solvent at any temperature can be estimated. (Coatema IP) Z ~ (P s - P p ) M r / T But still there are other influencing factors unknown (like the matrix of solids). Such factors have to be determined experimentally COATEMA Coating Machinery GmbH 203

204 Drying time Vapor pressure & evaporation rate Drying time depends on the solvent evaporation rate at demanded temperature. (Sufficient energy transfer to achieve this temperature may be presupposed.) A decisive factor for evaporation rate is vapor pressure. If drying is allowed near the solvent boiling temperature, there is no difference in vapor pressure for all solvents. But if by other reasons the drying temperature is limited, there are huge differences in vapor pressure. So the issue is to find the vapor pressure and evaporation rate for the given solvent at demanded temperature COATEMA Coating Machinery GmbH 204

205 Drying time Calculation of dryer length This is a practical example of a real calculation of dryer length for a 900µ wet coating based on solvent xylene at drying temperature 120 C. Sufficient energy transfer is supposed. The result was verified by trial. Coating data: coating thickness wet 900µ solvent Xylene 65% pure solvent thickness wet 585µ specific weight xylene solvent grammage web speed Evaporation data: vapor pressure xylene at 20 C 0.88 g/cm³ g/m² 0.13 m/min 880 Pa boiling temperature xylene 140 C vapor pressure at 120 C Pa relative molar mass xylene evaporation rate (according to Coatema method) Result (from web speed, grammage, evaporation rate): dryer length 1.64 g/m²s 0.68 m COATEMA Coating Machinery GmbH 205

206 Drying time Diffusion and Skinning Diffusion limit and Skinning Drying is limited by diffusion (at least in the final state of low residual solvent content) If the internal diffusion is slower than the evaporation from the surface, then a skin may be created The remaining diffusion through the skin may be slower than the wet diffusion by many orders of magnitude So the initial evaporation must be reduced by low temperature and/or by partially saturated atmosphere. Despite reduced evaporation the total drying time then may be shorter than at full initial evaporation COATEMA Coating Machinery GmbH 206

207 Drying Technology Temperature profile and uniformity Downweb temperature profiles can easily be realized by partitioning the dryer in different zones with different drying parameters: dryer 1 dryer 2 Temperature 1 Airflow 1 Temperature 2 Airflow 2 Temperature 3 Airflow 3 Temperature 4 Airflow 4 But temperature uniformity is difficult. Possible cause: Mixing of hot cool air at unintended leakages by Venturi effect. and Experience shows, that there is always a compromise: Good temperature uniformity requires low homogeneous air flow. High air flow results in less temperature uniformity COATEMA Coating Machinery GmbH 207

208 Drying technology Surface deterioration The air flow to remove the evaporating solvent may be laminar or turbulent. Fluctuations of the flow may deteriorate the surface of a low viscous liquid causing wavy or stochastic structures. nonuniform air flow with 10% fluctuations coating with orange skin surface (exaggerated) h For rough estimation it may be assumed, that 10% fluctuations of the dynamic (impact) pressure of the air flow compensate the hydrostatic pressure difference caused by the surface structures of the low viscous liquid: 10 ρ liquid g h = ½ ρ air v max ² v max = 20 (ρ liquid / ρ air ) g h Dynamic effects being influenced by viscosity are not calculated. So the estimation holds for very low viscous liquids only. Result: An orange skin of 1µ deterioration depth would be created by an air flow of 0.5 m/s with superimposed fluctuations of 10% COATEMA Coating Machinery GmbH 208

209 Drying technology Surface deterioration practical example: measured air speed in different dryers dryer setting display reading v (air) at slot exit v (air) at web surface remarks m³/h m/s m/s SC cm wide mini hot air dryer with slots from above CC cm wide hot air dryer with slots from above and below SM cm wide hot air floating dryer with 180 -shifted air cushion nozzles from above and below 100% 4,7 0,8 7 Slots 260 x 7 mm² slot length = web width only from top values measured at first slot 100% 4,6 1,6 48 Slots 83 x 5 mm² 24 from top 24 from bottom 100% 25 8 nozzles from top 8 nozzles from bottom 3 slots for each nozzle Center 800 x 7 mm² sides 800 x 4 mm² from the 100% setting the air speed can be reduced to any intended value by changing the ventilator settings and/or reducing the slot width. Surface deterioration thus can be avoided COATEMA Coating Machinery GmbH 209

210 Technologies Drying Technologies COATEMA Coating Machinery GmbH 210

211 Technologies Hot air technology combined functions of heating and vapor transport bulk heating by heat transfer from the surface overheating easily avoided by limited air temperature simple slot dryer wing shaped slot dryer wing shaped nozzle dryer with different nozzles COATEMA Coating Machinery GmbH 211

212 Technologies Hot air technology slot dryers with adjustable slots easy to clean COATEMA Coating Machinery GmbH 212

213 Technologies Drying Technologies Exhaust air Fresh air supply Dirt filter with radiator Circulation air fan COATEMA Coating Machinery GmbH 213

214 Technologies Drying Technologies COATEMA Coating Machinery GmbH 214

215 Technologies Drying Technologies COATEMA Coating Machinery GmbH 215

216 Technologies Hot air technology Floatation dryer single nozzle COATEMA Coating Machinery GmbH 216

217 Technologies IR Dryer I 1 = I 0 e ax I0 I 0 I 1 a x intensity in intensity out absorption coefficient layer thickness I COATEMA Coating Machinery GmbH 217

218 Technologies IR Dryer Courtesy Heraeus I 1 = I 0 e ax I0 I 0 I 1 a x intensity in intensity out absorption coefficient layer thickness I1 high absorption optimum absorption low absorption Relative intensity of radiators at different wavelengths COATEMA Coating Machinery GmbH 218

219 Technologies IR Dryer IR-radiation separate functions of heating and vapor transport full bulk heating by IR-absorption absorption dependent on wavelength overheating to be avoided by surface temperature sensor control problem: temperature homogeneity COATEMA Coating Machinery GmbH 219

220 Technologies IR & Hot air dryer Combined hot air / IR dryer COATEMA Coating Machinery GmbH 220

221 Technologies Comparison of technologies Courtesy Adphos Summary: Short wave NIR can be of great advantage, but only if applicable. Applicability depends on coating liquid and substrate. (The table focusses on applicable cases.) COATEMA Coating Machinery GmbH 221

222 Technologies Diffusion-Skinning-Delamination limited diffusion if the internal diffusion is slower than the evaporation from the surface a skin may be created the remaining diffusion through the skin may be slower than the wet diffusion by many orders of magnitude so the initial evaporation must be limited - by low temperature and/or - by partially saturated atmosphere insufficient adhesion and layer tension may cause delamination COATEMA Coating Machinery GmbH 222

223 UV-technology Crosslinking UV Basics and Technology The Electromagnetic Spectrum Visible Light IR-A IR-B IR-C nm COATEMA Coating Machinery GmbH 223

224 UV-technology Crosslinking UV Basics and Technology Penetration of the Material by UV Radiation UV C UV B UV A Material COATEMA Coating Machinery GmbH 224

225 UV-technology Crosslinking Discharge Media and Pressure Ranges Low pressure lamps 10-6 bar Mercury Hg fluorescent additive Xenon vaporized Metal High pressure lamps 1-10 bar Mercury Metall halide Xe vaporized Metal Highest pressure lamps >10 bar Hg-short arc Hg-capillary Xe-short arc COATEMA Coating Machinery GmbH 225

226 UV-technology Crosslinking Typical Output 10 % heat loss of the electrodes 80 % Plasma radiation 10 % heat loss 30 % UV 40 % IR COATEMA Coating Machinery GmbH 226

227 UV-technology Crosslinking Drying without heating - BlueLight UV Curing Systems BlueLight UV Curing System consisting of: BlueLight UV Cassette (with optional inertisation) with Excimer UV Lamp installed (variable radiation length) Power Supply (variable power class) Cooling unit COATEMA Coating Machinery GmbH 227