nordson polymer processing systems - aimcal.org · curtain slide die does outperform in several...
TRANSCRIPT
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Nordson Polymer Processing Systems
Slide Curtain Die Technology what you need to know
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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
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End Markets: Consumer Non-Durables, Durables, Technology….Every Day You Experience the Value We Bring
Other Markets - Agriculture, Furniture, Industrial, LEDs, Containers, Aerospace
Nordson’s 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
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Coating Technologies
4 |June 2016
Curtain & Slide Curtain Coating
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Coating Technology Overview
Technology
Min Viscosit
y cPs
Max Viscosit
y cPs
Min Line Speed
fpm
Max Line Speed
fpmMin Wet
Thick µmMax Wet Thick µm
Coating Uniformity
# Layers
Patch coat Cost
Required Expertis
ePremeteredSlot Die Fixed lip* 1 175,000 0.5 2000
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Coating Parameters
Coating Processes Coating Chemistry Pretreatment Substrate Drying/Curing
•Coating Accuracy•Layer Thickness•Single Layer•Multiple Layer•Stripe Coating•Transfer Coating•Direct Coating•Coating Systems•Substrate Speed
•Rheology•Viscosity•Solid Content•Type of Solvent•Adhesion/Cohesion•Shear ratio•Pigmented•Surface tension
•Corona•Plasma•Cleaning
•Surface energy•Roughness•Surface Structure•Contact angle•Web stability
•Convection Drying•Contact Drying•Infrared Drying•Sintering•NIR•High Frequency•UV-Crosslinking•EBeam
Environment Finishing
•Humidity•Temperature•Inert Conditions
•Calandering•Embossing•Slitting
6 |June 2016
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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):
ṁ =ρ Vw h b
where ṁ is the mass flow per meter of substrate width, ρ the fluid density, Vwthe substrate velocity, h the height/thickness and b the width of the applied layer.
Coating principles
7 |June 2016
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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.
Coating Technology Comparison
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Coating Technology Comparison
Technology
Min Viscosit
y cPs
Max Viscosit
y cPs
Min Line Speed
fpm
Max Line Speed
fpmMin Wet
Thick µmMax Wet Thick µm
Coating Uniformity
# Layers
Patch coat Cost
Required Expertis
ePremeteredSlot Die Fixed lip* 1 175,000 0.5 2000
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Coating Technology Comparison
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 µm 2% 1
Air Knife Metering 1 - 500 cps 15 - 150m/min 1 - 200 µm 5% 1Knife Over Roll 100 - 50000 cps 2 - 150m/min 26 - 750 µm 8% 1Gravure Direct Chamber 10 - 2000 cps 8 - 750m/min 1 - 75 µm 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 µm
1 - 2000 µm
14 - 500 µm
3- 20 µm
1 - 500 µm
3
18
1
1
1
2%
2%
10%
Coating Technology Comparison
Pre-metered
Specialty Coating
0,5 - 600 m/min 1 - 2000 µm
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
Coating Technology Comparison
10
9
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3
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Pre-meteredRankingRankingRankingRankingRankingSummary
ASlot Die Fixed Lip1 -175000 cps90,5 - 600 m/min81 - 3000 µm102%93945
BSlot Die Adjustable Lip1 -250000 cps100,5 - 600 m/min81 - 2000 µm92 - 4%73943
CCurtain Slide Die10 - 5000 cps4100 - 1800 m/min101 - 2000 µm91%10181043
Self-metered Roll Coating
DReverse Roll Coating200 - 40000 cps75 - 350 m/min614 - 500 µm62%81835
Self-metered Doctor Roll-Coater
EGravure Direct Reverse20 - 13000 cps52 - 350m/min73- 20 µm22%81830
FGravure Direct Chamber10 - 2000 cps28 - 750m/min91 - 75 µm32%81830
GKnife Over Roll100 - 50000 cps82 - 150m/min426 - 750 µm88%51833
HAir Knife Metering1 - 500 cps115 - 150m/min31 - 200 µm45%61822
Specialty Coating
ISpray10 - 30000 cps620 - 150m/min250 - 340 µm52%81829
JMicro Gravure Coating1 - 4000 cps31 - 250m/min51 - 500 µm710%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
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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
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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 (ṁ)which is fed by the pump into
the Slide Curtain Die.
12 |June 2016
Slide Curtain Die Technology
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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)
Slide Curtain Die Technology
13 |June 2016
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• 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 Die Technology
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Slide Curtain Die•Manifold design•Slot gap tolerance•Lip inserts
Edge-Guide•Length•Water port•Vacuum port•Neck-in,edge-bead
Fluid Delivery System•Viscosity•Solid content•Bubble-free•Pulse-free
Web- Flow /Speed•Web-wind•Constant speed•Pulse-free
Impingement Zone•Air boundary layer•Vacuum
15 |June 2016
Slide Curtain Die Technology
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Manifold Design, Flatness and Gap Tolerance
µm 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
Slide Curtain Die Technology
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Uniform & Stable Curtain, •Based on a Curtain Coating capable fluid•Pulse-free and bubble free fluid delivery
avoiding waves and voids•Well designed Die manifold•Well designed edge-guides
17 |June 2016
Minimized Neck-in, No Edge-bead•Distance of edge-guide to substrate•Liquid gas interface•Liquid solid interface•Dynamic contact line
Single or Multiple Layer Design •Endplate with edge-guide integration for different length•Possible deckling or application widthadjustments
Slide Curtain Die Technology
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18 |June 2016
Slide Curtain Die Technology
Attribute Slide Curtain Die
Lip Gap Adjustment Fixed
Gap Accuracy A - ±2.5 µm, AA -±1.5 µm, AAA -±0.5 µm
Coating Thickness (wet) ≥ 1 µm
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. 80°C
Viscosity Range ≥ 100 mPas, ≤ 10000 mPas
Specific Flow Rate ≥ 2cm³/cms
Capabilities Matrix
Tabelle1
Capabilities Matrix
AttributeSlide Curtain Die
Lip Gap AdjustmentFixed
Gap AccuracyA - ±2.5 µm, AA -±1.5 µm, AAA -±0.5 µm
Coating Thickness (wet)≥ 1 µm
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. 80°C
Viscosity Range≥ 100 mPas, ≤ 10000 mPas
Specific Flow Rate≥ 2cm³/cms
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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
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Curtain vs. Gravure, AIMCAL 2012
20 |June 2016
Slide Curtain Die Technology, Feedback
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• 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 application…Fluid 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
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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