About us COAT C EMA M C o C ating Ma M c a hine h r ine y r GmbH b H ww w w w. w coa o t a em e a.
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1 About us COATEMA Coating Machinery GmbH 1
2 Summary Introduction Coatema Lab, pilot and production tools Technologies & Processes - Printing systems - Scribing/Patterning systems - Coating systems - Coating processes - Coating background in textiles - Drying, curing & crosslinking Upscaling from Lab2Fab Summary COATEMA Coating Machinery GmbH 2
3 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 3
4 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 4
5 Introduction Coatema Our Headquater in Dormagen COATEMA Coating Machinery GmbH 5
6 Introduction Coatema Our worldwide service COATEMA Coating Machinery GmbH 6
7 Introduction Coatema Our markets Printed Electronics Prepreg Membranes Renewables Textile Film Paper Glass COATEMA Coating Machinery GmbH 7
8 Introduction Coatema Our customers COATEMA Coating Machinery GmbH 8
9 Introduction Coatema Our latest awards COATEMA Coating Machinery GmbH 9
10 Introduction Coatema Our R&D partners COATEMA Coating Machinery GmbH 10
11 Introduction Coatema Our innovations through times *Projects of the last 5 years ProLiBat COATEMA Coating Machinery GmbH 11
12 Introduction Coatema Our know-how Author: Andreas Giessmann Co-Author: Andreas Giessmann Chapter: Anwendungen COATEMA Coating Machinery GmbH 12
13 Introduction Coatema Our business units Lab Pilot Production Custom COATEMA Coating Machinery GmbH 13
14 R&D Centre Our R&D centre 1200 qm 9 Pilot plants 1 production line 1 Click&Coat line Working widths: mm Qualified personnel Laboratories Testing facilities COATEMA Coating Machinery GmbH 14
15 R&D Centre Our R&D centre Purpose 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 Example Slot die impregnation and curing of a new prepreg material for the automotive industry COATEMA Coating Machinery GmbH 15
16 R&D Centre Our R&D solution Coatema solution path Chemical solution Lab trials Your inquiry Lab solution Taylor-made for your product idea Process solution COATEMA Coating Machinery GmbH 16
17 R&D Centre Our current equipment Multifunctional Coatingline Universal Coating Plant 2 x Smartcoater Basecoater and inert Bascecoater Easycoater 15 Click&Coat TM units Filter/ Dissolver COATEMA Coating Machinery GmbH 17
18 Lab, pilot and production tools COATEMA Coating Machinery GmbH 18
19 Lab, Pilot and production tools Test Solution With Slot Die COATEMA Coating Machinery GmbH 19
20 Lab, Pilot and production tools Test Solution R2R COATEMA Coating Machinery GmbH 20
21 Lab, Pilot and production tools The Easycoater COATEMA Coating Machinery GmbH 21
22 Lab, Pilot and production tools The Thin Film Coater & Printer COATEMA Coating Machinery GmbH 22
23 Lab, Pilot and production tools The Smartcoater COATEMA Coating Machinery GmbH 23
24 Lab, Pilot and production tools The Basecoater 3rd Generation COATEMA Coating Machinery GmbH 24
25 Scaling up new technologies The Click&Coat COATEMA Coating Machinery GmbH 25
26 Lab, Pilot and production tools R2R in nitrogen environment COATEMA Coating Machinery GmbH 26
27 Lab, Pilot and production tools The Deskcoater COATEMA Coating Machinery GmbH 27
28 Lab, Pilot and production tools The Verticoater COATEMA Coating Machinery GmbH 28
29 Lab, Pilot and production tools The Linecoater COATEMA Coating Machinery GmbH 29
30 Lab, Pilot and production tools Bespoken Lab concepts COATEMA Coating Machinery GmbH 30
31 Lab, Pilot and production tools Mixing equipment COATEMA Coating Machinery GmbH 31
32 Lab, Pilot and production tools Production lines COATEMA Coating Machinery GmbH 32
33 Lab, Pilot and production tools Coating Stations COATEMA Coating Machinery GmbH 33
34 Lab, Pilot and production tools Coating Stations COATEMA Coating Machinery GmbH 34
35 Lab, Pilot and production tools Coating Stations COATEMA Coating Machinery GmbH 35
36 Lab, Pilot and production tools Coating Lines COATEMA Coating Machinery GmbH 36
37 Lab, Pilot and production tools Coating Lines COATEMA Coating Machinery GmbH 37
38 Lab, Pilot and production tools Coating Lines COATEMA Coating Machinery GmbH 38
39 Lab, Pilot and production tools Coating Lines COATEMA Coating Machinery GmbH 39
40 Upscaling from Lab2Fab Going to Fab - Technologies COATEMA Coating Machinery GmbH 40
41 Technologies & Processes COATEMA Coating Machinery GmbH 41
42 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 42
43 Technologies & Processes From Lab2Fab COATEMA Coating Machinery GmbH 43
44 Upscaling from Lab2Fab Going to Fab - Technologies COATEMA Coating Machinery GmbH 44
45 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 45
46 Technologies & Processes Printing Systems COATEMA Coating Machinery GmbH 46
47 Technologies & Processes Printing Parameters COATEMA Coating Machinery GmbH 47
48 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 48
49 Technologies & Processes Printing Systems Gravure printing Flexo printing Screen printing COATEMA Coating Machinery GmbH 49
50 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 50
51 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 51
52 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 52
53 Technologies & Processes 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 1 st printing station guiding frame in front of 1 st printing station dancing roller COATEMA Coating Machinery GmbH 53
54 Technologies & Processes Registration control system COATEMA Coating Machinery GmbH 54
55 Technologies & Processes Scribing/Patterning Systems COATEMA Coating Machinery GmbH 55
56 Technologies & Processes Laser Patterning System Laser Parameters Scribing Speed 2-10 m/min Structure width µm 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 COATEMA Coating Machinery GmbH 56
57 Technologies & Processes 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 COATEMA Coating Machinery GmbH 57
58 Edge Delete Technologies & Processes Laser Patterning System P 3 Top contact TCO P 1 P 2 P 4 Absorber 1 Back contact Barrierer Substrat (Metall, Polymer) COATEMA Coating Machinery GmbH 58
59 Technologies & Processes Nanoimprinting System Nanoimpreinting Parameters Printing Speed 0,1-20 m/min Nip Pressure Ink viscosity Layer Thickness Feature Size Resolution COATEMA Coating Machinery GmbH 59
60 Technologies & Processes Nanoimprinting System COATEMA Coating Machinery GmbH 60
61 Technologies & Processes Nanoimprinting System 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 61
62 Technologies & Processes Hot embossing System Hot embossing Parameters Printing Speed 0,1-3 m/min Nip Pressure Register controlled COATEMA Coating Machinery GmbH 62
63 Technologies & Processes Hot embossing System COATEMA Coating Machinery GmbH 63
64 Technologies & Processes Photolithographic System COATEMA Coating Machinery GmbH 64
65 Technologies & Processes Photolithographic System COATEMA Coating Machinery GmbH 65
66 Coating Systems COATEMA Coating Machinery GmbH 66
67 Technologies & Processes Coating Systems Knife Double Side Commabar Case Knife Hotmelt Slot Die Engraved Roller 3 Roller Combi Micro Roller 5 Roller Reverse Roll Slot Die Curtain Coating 2 Roller Combi Powder Scatterning Dipping Rotary Screen COATEMA Coating Machinery GmbH 67
68 Technologies & Processes Coating Parameters Coating Chemistry Coating Processes Process control Drying Rheology Viscosity Viscoelasticity 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 68
69 Processes Definition of Coating Systems Category of coating methods Self-metered Doctored Pre-metered Examples of coating methods belong to the category - Dip roll - Nip forward roll - Reverse roll - Mayer rod - Blade/knife - Air knife - Dip & scrape -Slot die - Slide curtain - Spray Characteristics Wet thickness is determined the conditions of the coating meniscus Post applicator device determines the wet thickness All the ink fed into an applicator is transferred to the web COATEMA Coating Machinery GmbH 69
70 Technologies & Processes Slot Die System COATEMA Coating Machinery GmbH 70
71 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 71
72 Technologies & Processes Slot Die System OPV slot die High precision slot die Meniscus mode COATEMA Coating Machinery GmbH 72
73 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 73
74 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 74
75 Coating Processes COATEMA Coating Machinery GmbH 75
76 Technologies Drying Technologies Drying with hot air technology COATEMA Coating Machinery GmbH 76
77 Technologies Drying Technologies COATEMA Coating Machinery GmbH 77
78 Drying Topics General tasks of drying Substrate Coating Heat transfer Vapor removal 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 COATEMA Coating Machinery GmbH 78
79 Drying Topics Drying systems: hot air technology combined functions of heating and vapor transport bulk heating by heat transfer from the surface simple slot dryer overheating easily avoided by limited air temperature wing shaped slot dryer wing shaped nozzle dryer with different nozzles COATEMA Coating Machinery GmbH 79
80 Drying Topics Drying systems: hot air technology Floating dryer single nozzle COATEMA Coating Machinery GmbH 80
81 Technologies Drying Technologies Exhaust air Fresh air supply Dirt filter with radiator Circulation air fan COATEMA Coating Machinery GmbH 81
82 Technologies Drying Technologies COATEMA Coating Machinery GmbH 82
83 Technologies Drying Technologies COATEMA Coating Machinery GmbH 83
84 Drying Topics Drying systems: IR technology IR-radiation 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 COATEMA Coating Machinery GmbH 84
85 Drying Topics Drying systems: IR technology Courtesy Heraeus I0 I1 I 0 I 1 a x intensity in intensity out absorption coefficient layer thickness COATEMA Coating Machinery GmbH 85
86 Technologies Drying Technologies IR-Sinter unit COATEMA Coating Machinery GmbH 86
87 Drying Topics Infrared dryers Combined hot air / IR dryer COATEMA Coating Machinery GmbH 87
88 Drying Topics Microwave dryers same pros and cons as IR, but even exaggerated complex system advantages for very thick layers only COATEMA Coating Machinery GmbH 88
89 COATEMA Coating Machinery GmbH THANK YOU Roseller Str. 4 D Dormagen / tkolbusch@coatema.de COATEMA Coating Machinery GmbH 89
90 COATEMA Coating Machinery GmbH 90
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