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Nordson Polymer Processing Systems

Slide Curtain Die Technology what you need to know

Topics

2 |June 2016

Introduction

Topics

End Markets

Coating Technologies

Coating Parameters

Coating Technology Overview

Coating Principles

Coating Technology Comparison

Slide Curtain Die Technology

Feedback

Summary

Different literatures are indicating different values of parameters and performances so displayed numbers may vary with your data and experience

End Markets: Consumer Non-Durables, Durables, Technology.Every Day You Experience the Value We Bring

Other Markets - Agriculture, Furniture, Industrial, LEDs, Containers, Aerospace

Nordsons Current and Potential Curtain Coating Markets

Disposable Hygiene

Flexible Packaging

Rigid Packaging

Appliances

Automotive

Construction

Electronics Displays

Paper

Solar

Battery

Tape & Label

3 |June 2016

Coating Technologies

4 |June 2016

Curtain & Slide Curtain Coating

Coating Technology Overview

Technology

Min Viscosit

y cPs

Max Viscosit

y cPs

Min Line Speed

fpm

Max Line Speed

fpmMin Wet

Thick mMax Wet Thick m

Coating Uniformity

# Layers

Patch coat Cost

Required Expertis

ePremeteredSlot Die Fixed lip* 1 175,000 0.5 2000

Coating Parameters

Coating Processes Coating Chemistry Pretreatment Substrate Drying/Curing

Coating AccuracyLayer ThicknessSingle LayerMultiple LayerStripe CoatingTransfer CoatingDirect CoatingCoating SystemsSubstrate Speed

RheologyViscositySolid ContentType of SolventAdhesion/CohesionShear ratioPigmentedSurface tension

CoronaPlasmaCleaning

Surface energyRoughnessSurface StructureContact angleWeb stability

Convection DryingContact DryingInfrared DryingSinteringNIRHigh FrequencyUV-CrosslinkingEBeam

Environment Finishing

HumidityTemperatureInert Conditions

CalanderingEmbossingSlitting

6 |June 2016

The decision to utilize a coating technology needs to be analyzed against set criteria to determine best fit.

Awareness of coating techniques and technologies is required.

An awareness of coating techniques, technologies and systems allow for new adaptations and application to new market opportunities.

Precision of the applied layer thickness is essential for some substrates in the coating industry, especially for coatings with functional layers.

With these, the coated wet layer thickness is determined by the mass flow rate and the known substrate velocity Vw, (web velocity):

= Vw h b

where is the mass flow per meter of substrate width, the fluid density, Vwthe substrate velocity, h the height/thickness and b the width of the applied layer.

Coating principles

7 |June 2016

8 | |

In terms of application technology only few parameters are taken in consideration to benchmark the right technology.

In our comparison we are differentiating between pre-metered and self-metered coating technologies

Benchmark parameters are

Viscosity range, Line speed Thickness Coating uniformity Number of functional layers

What is best and what is worst?

The broader the range in each criteria the more beneficial it is. In terms of coating uniformity we put the most precise tolerance as best.



Technology

Min Viscosit

y cPs

Max Viscosit

y cPs

Min Line Speed

fpm

Max Line Speed

fpmMin Wet

Thick mMax Wet Thick m

Coating Uniformity

# Layers

Patch coat Cost

Required Expertis

ePremeteredSlot Die Fixed lip* 1 175,000 0.5 2000


10

9

8

7

6

5

4

3

2

1

Ranking Ranking Ranking Ranking Ranking SummaryA 9 8 10 9 9 45B 10 8 9 7 9 43C 4 10 9 10 10 43

D 7 6 6 8 8 35

E 5 7 2 8 8 30F 2 9 3 8 8 30G 8 4 8 5 8 33H 1 3 4 6 8 22

I 6 2 5 8 8 29J 3 5 7 4 8 27

Spray 10 - 30000 cps 20 - 150m/min 50 - 340 m 2% 1

Air Knife Metering 1 - 500 cps 15 - 150m/min 1 - 200 m 5% 1Knife Over Roll 100 - 50000 cps 2 - 150m/min 26 - 750 m 8% 1Gravure Direct Chamber 10 - 2000 cps 8 - 750m/min 1 - 75 m 2% 1

2%

1%2 - 4% 3

Self-metered Roll Coating

Slot Die Fixed Lip

Curtain Slide Die

Reverse Roll Coating

Gravure Direct Reverse

Slot Die Adjustable Lip 1 -250000 cps

Self-metered Doctor Roll-Coater

0,5 - 600 m/min

100 - 1800 m/min

Micro Gravure Coating

1 -175000 cps

10 - 5000 cps

200 - 40000 cps

20 - 13000 cps

1 - 4000 cps

5 - 350 m/min

2 - 350m/min

1 - 3000 m

1 - 2000 m

14 - 500 m

3- 20 m

1 - 500 m

3

18

1

1

1

2%

2%

10%


Pre-metered

Specialty Coating

0,5 - 600 m/min 1 - 2000 m

1 - 250m/min

viscosity range line speed thickness coating uniformity number layers

B

A

I

G

D

E

J

C

F

H

B A

C

F

E

D

J

G

H

I

A

B C

G

J

D

I

H

F

E

C

A

D E F I

B

H

G

J

C

A B

D E F G H I J

10 |June 2016

Technology based decision process can determine top 3 options that need to be

evaluated for the performance vs. cost to make final decision

Tabelle1


10

9

8

7

6

5

4

3

2

1

Pre-meteredRankingRankingRankingRankingRankingSummary

ASlot Die Fixed Lip1 -175000 cps90,5 - 600 m/min81 - 3000 m102%93945

BSlot Die Adjustable Lip1 -250000 cps100,5 - 600 m/min81 - 2000 m92 - 4%73943

CCurtain Slide Die10 - 5000 cps4100 - 1800 m/min101 - 2000 m91%10181043

Self-metered Roll Coating

DReverse Roll Coating200 - 40000 cps75 - 350 m/min614 - 500 m62%81835

Self-metered Doctor Roll-Coater

EGravure Direct Reverse20 - 13000 cps52 - 350m/min73- 20 m22%81830

FGravure Direct Chamber10 - 2000 cps28 - 750m/min91 - 75 m32%81830

GKnife Over Roll100 - 50000 cps82 - 150m/min426 - 750 m88%51833

HAir Knife Metering1 - 500 cps115 - 150m/min31 - 200 m45%61822

Specialty Coating

ISpray10 - 30000 cps620 - 150m/min250 - 340 m52%81829

JMicro Gravure Coating1 - 4000 cps31 - 250m/min51 - 500 m710%41827

viscosity range

line speed

thickness

coating uniformity

number layers

B

A

I

G

D

E

J

C

F

H

B

A

C

F

E

D

J

G

H

I

A

B

C

G

J

D

I

H

F

E

C

A

D

E

F

I

B

H

G

J

C

A

B

D

E

F

G

H

I

J

The pre-metered coating technology outperform the self-metered technology

Based on its design and principle , multiple layer application is just available with the pre-metered technology

The range of coating thickness for the pre-metered technology is rather huge compared to the self-metered technology

Although Slide Curtain Die technology is not rated as high as Slot Die technology, Curtain Slide Die does outperform in several other process criterias, suc as:

Line speed, layer thickness, coating uniformity, number of layers

Slide Curtain Coating technology has been adapted to service needs in multiple markets and applications for thinner, multiple functional layers with improved coat weight uniformity at high speeds.

Slide Curtain Coating technology provides innovative tools that will help coating companies improve precision, tackle new markets, and develop new processes.

WHAT IS BEHIND THIS TECHNOLOGY?

Coating Technology Comparison, Conclusion

11 |June 2016

Slide Curtain Die Technology is a pre-metered method that creates an uninterrupted curtain of fluid that falls onto a substrate.

The thickness (h) of the layer is mainly determined by the speed (Vw) of the substrate and the amount ()which is fed by the pump into

the Slide Curtain Die.

12 |June 2016


Benefits and Advantages

It is a pre-metered coating process for precisely controlled fluid amounts

Excellent coating method to generate an excellent cross-Web uniformity in the whole range of speeds and coat weights.

Coat weight accuracy determines mainly by the design, dimensions, fluid flow characteristics and manufacturing tolerances of the die.

Non-Contact application process

Multiple Layer process possible within one pass

Possibilities of two component applications (coating color or cross-linking agent)


13 |June 2016

The specific flow rate is important to achieve a stable process and to produce a minimum coat weight at a given web speed.

Curtain stability is important and crucial for low coat weights and at low line speed.

Curtain Coating creates an even coating even on uneven surfaces

It is possible to split one big layer into a multiple layer to improve the entire process

It is also possible to combine layers with different thicknesses

14 |June 2016


Slide Curtain DieManifold designSlot gap toleranceLip inserts

Edge-GuideLengthWater portVacuum portNeck-in,edge-bead

Fluid Delivery SystemViscositySolid contentBubble-freePulse-free

Web- Flow /SpeedWeb-windConstant speedPulse-free

Impingement ZoneAir boundary layerVacuum

15 |June 2016


Manifold Design, Flatness and Gap Tolerance

m A B C D ELOW -0.334819 -0.554183 -0.219364 -0.069273 -0.037523HIGH 0.115455 0.000000 0.496456 0.935184 0.871684DIFF 0.450274 0.554183 0.715820 1.004457 0.909206

16 |June 2016


Uniform & Stable Curtain, Based on a Curtain Coating capable fluidPulse-free and bubble free fluid delivery

avoiding waves and voidsWell designed Die manifoldWell designed edge-guides

17 |June 2016

Minimized Neck-in, No Edge-beadDistance of edge-guide to substrateLiquid gas interfaceLiquid solid interfaceDynamic contact line

Single or Multiple Layer Design Endplate with edge-guide integration for different lengthPossible deckling or application widthadjustments


18 |June 2016


Attribute Slide Curtain Die

Lip Gap Adjustment Fixed

Gap Accuracy A - 2.5 m, AA -1.5 m, AAA -0.5 m

Coating Thickness (wet) 1 m

Coating Weight Accuracy 1% MD & CD

Coating Principle None Contact

Coating Speeds 150 m/min - 1800m/min

max. Coating Width 6400mm

Number of Layers usually 1-3 layers, possible 18 layers and more

max. Operating Temperatur max. 80C

Viscosity Range 100 mPas, 10000 mPas

Specific Flow Rate 2cm/cms

Capabilities Matrix

Tabelle1

Capabilities Matrix

AttributeSlide Curtain Die

Lip Gap AdjustmentFixed

Gap AccuracyA - 2.5 m, AA -1.5 m, AAA -0.5 m

Coating Thickness (wet) 1 m

Coating Weight Accuracy 1% MD & CD

Coating PrincipleNone Contact

Coating Speeds150 m/min - 1800m/min

max. Coating Width 6400mm

Number of Layersusually 1-3 layers, possible 18 layers and more

max. Operating Temperaturmax. 80C

Viscosity Range 100 mPas, 10000 mPas

Specific Flow Rate 2cm/cms

19 |June 2016

Superior coverage and clearly reducedcloudiness

Best coating color distribution (CD & MD)

Improved visual appearance by coatinglayer

Significant higher solid content (62-64%)

No speed limit ( >> 500m/min)

Wide coat weight range (11 to 20 gsmwithout any difficulty)

Very good runnability (no web break during curtain coater use since start-up)

Furnish cost reduced

Production increased due to increasemachine speed

Energy savings due to increased solid content 42% - 62%

Coating cost reduction(reducedpigment cost at maintained quality due to superior coverage

Curtain vs. Air Knife Coater, PaperCon 2011 Northern Kentucky Convention Center

Curtain Coating is a Green Technology

Energy savings due to higher machine efficiency and less drying requirements

Increased use of recycled fibres due to improved machine runnability and coatingcoverage

Slide Curtain Die Technology, Feedback

Curtain vs. Gravure, AIMCAL 2012

20 |June 2016

Slide Curtain Die Technology, Feedback

Based on coating parameters esp. process parameters benchmark the most promising application technology

Pre-metered outperforms the self-metered application technology, therefore Slide Curtain / Curtain Die technology could be the best fit

Fluids needs to be capable for Curtain Coating Die applicationFluid chemistry has to be checked

Production and machine speed meets or is above the specific flow rate

Potential to increase the solid content, enables to increase speed or to save drying energy

Single or multiple functional layer application always considering the drying capabilities

High performance and high accuracy application requirements

Slide Curtain Die Technology, Summary

21 |June 2016

Slide Curtain Die is a Green Technology

Nordson Polymer Processing Systems

Slide Curtain Coating Dies within Fluid Coating Application Systems

Nordson Polymer Processing Systems Slide Curtain Die Technology what you need to knowTopicsEnd Markets: Consumer Non-Durables, Durables, Technology .Every Day You Experience the Value We BringCoating TechnologiesCoating Technology OverviewCoating ParametersCoating principlesCoating Technology ComparisonCoating Technology ComparisonCoating Technology ComparisonCoating Technology Comparison, ConclusionSlide Number 12Slide Number 13Slide Number 14Slide Number 15Manifold Design, Flatness and Gap Tolerance Slide Number 17Slide Number 18Slide Number 19Slide Number 20Slide Number 21Slide Number 22

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