AIMCAL - Summer School India

AIMCAL Summer School India 2007

August 20-21, 2007 | Pragati Maidan Exhibition Centre | New Delhi, India

Summer School Schedule

Summer School India consists of three tracks.
Click on session title to view details.

TRACK	Monday August 20 8 am - 5 pm	Tuesday August 21 8 am - 5 pm
Web Handling & Converting	Web Control Dr. Dilwyn Jones	Winding and Defect Elimination Dr. Dilwyn Jones
Vacuum Coating	Vacuum Deposition - Substrates, Pre-treatments & Winding Webs In Vacuum Dr. Charles Bishop	The Basics Of Vacuum Deposition, Sources & Substrate Heat Load Dr. Charles Bishop
Web Coating & Drying	Coating Solution Preparation to Improve Quality Dr. Ed Cohen	Coating Defects, Troubleshooting, Causes And Cures Dr. Ed Cohen

Web Handling and Converting Track

These sessions cover the elements of web behaviour and winding that are common to all coating and converting operations. The first day covers web tension and lateral position, and the second covers roll porduction and faults arising from winding and web handling. Delegates can attend either day or both. The fundamental science is explained in basic terms, leading to guidance on how to diagnose and solve real problems, and indicating where calculations can be useful.

Day One - Web Control

Introduction

What is web handling?
Typical problems
Information sources and software
Web materials and important properties
Friction and air entrainment

Tension

Tension definition and causes
Tension measurement methods
Mechanical effects of tension
Tension management
Recommended tension values

The link between speed and strain
Traction of web on rollers
Roller and surface design
Nips
Vacuum pull rollers

Web Line Control

Line speed setting
Speed and length measurements
Tension isolation methods
Tension control systems
Draw (speed) control
Starting and stopping

Steering and Guiding

Steering principles
Passive guiding
Active guiding
Sensors
Guide Performance

Day Two - Winding and Defect Elimination

Roll geometry
Winder types
Lay-on rollers
Stresses in wound rolls
Control of winding parameters

Measuring wound rolls
Roll hardness
Web faults and deformation
Hardness-related faults
Cores

Stacking faults
Inter-layer slippage
Blocking
High spot, high edge
Wrinkles
Starring

Wrinkling mechanisms
Wrinkle types: causes and cures
Wrinkle flattening on rollers
Web spreading objectives
Types of spreader and their performance

Bagginess and camber
Viscoelastic materials
Highly compressible materials
Effects of temperature and moisture
Curl

BACK TO TOP

Vacuum Coating

Vacuum Deposition - Substrates, Pre-treatments & Winding Webs In Vacuum
Dr. Charles Bishop, C.A.Bishop Consulting Ltd.
Course Overview
The vacuum coating sessions are designed to provide a logical succession from substrate to process to end performance of vacuum coated flexible webs. The sessions build on the fundamentals of the technology to provide in depth understanding of the technology, its application and the end results.
Session Topics

Day 1

Substrate quality & how if may affect winding & coated product quality
- Roll quality
- Surface quality
Special attention will be given to how the material specification/quality can influence the barrier performance of coatings (especially ultra barrier)Substrate pre-treatments
Types of atmospheric pre-treatment
- Flame
- Corona
- Atmospheric plasma
- Coatings
Types of vacuum pre-treatment
- Plasma
- UV
- Polymer coatings
Web cleaning processes
- Brushes
- Air jets/vacuum
- Tack rolls
Nucleation and Film Growth
Winding webs in vacuum
- Basics of winding systems
- Static
- Gas wedge
- Tension & load cells

The Basics Of Vacuum Deposition, Sources & Substrate Heat Load
Dr. Charles Bishop, C.A.Bishop Consulting Ltd.

Course Overview
The vacuum coating sessions are designed to provide a logical succession from substrate to process to end performance of vacuum coated flexible webs. The sessions build on the fundamentals of the technology to provide in depth understanding of the technology, its application and the end results.

Session Topics

Day 2

The basics of vacuum systems
Sources
- Evaporation of Aluminium from resistance heated boats.
- Magnetron sputtering - the basics
- E-beam evaporation - the basics
- PECVD - the basics
- Other sources - the basics
- Slot sources - Zn, ZnS, OLED polymers
- Induction heated sources
- Comparison of sources
- Deposition rates
- Uniformity
Control of heat load
Troubleshooting

Web Coating & Drying
Attend one or both days of introductory sessions on vacuum coating, web coating and film substrates.

Coating Solution Preparation to Improve Quality
Dr. Ed Cohen, Edward D. Cohen Consulting

Course Overview
An essential requirement to produce a high quality low cost web coating product is to insure that coating solution preparation process, produces defect free solutions which meet all the requirements of the coating application and drying process. Solution coatabilty and reproducibility, physical defects, coater oprability and many surface features of the coated product critically depend upon the properties of the coating solution. If the coating solutions are in any way defective, the subsequent processes steps in the web coater will not eliminate these defects and defective product is guaranteed.

In this course, the unit operations and equipment typically used in the fluid handling process to mix and transport coating solutions to the applicator will be presented. The important solution rhelogical properties will be defined and measurement methods presented In addition, the effect of coating solution properties on defects will be discussed.

Session Topics

Day 1, June 19

Unit Operations of Solution Preparation and Delivery: Determining the need, selecting the equipment and vendor, and achieving control

Mixing: Scale-up, off-line, in-line.
Filtration
Deaeration
Pulsation Dampening
Temperature control
Pressure control
Viscosity control
Pumping

What are the important solution properties for a robust coating process and how are they measured?

Rheology, Surface Tension, Density, Dissolved gas content, Impurities

How are common coating defects related to these properties?

Streaks Spots, Comets, Edge Quality, Mottle, Skips. Coating weight

How do we keep properties in control after the solution is prepared?

Role of additives
Effect of additives on initial adhesion
Effect of additives on pretreatments

What materials are used as Coating aids?

o Surfactants, Thickeners, Stabilizers, foam suppressors?

Problems of particular substrates

Polyester film, polypropylene etc
Pretreatments including corona, plasma and flame
Priming
Role of surface analysis

Cleaning mixing and delivery equipment

Raw materials

Coating Defects, Troubleshooting Causes and Cures
Dr. Ed Cohen, Edward D. Cohen Consulting

Course Overview
This session provides guidelines to plant engineers and industrial scientists responsible for ensuring the quality of thin wet coatings is fit for end use. Practical advice is given on detecting and characterising defects and troubleshooting methods. The scope covers all main aspects of a coating process including provision of the substrate material, solution supply, coating and drying.

Session Topics

Defect Diagnostics
Defects due to Solution Supply
Defects due to Substrate
Defects due to Coating -General
Defects due to Coating -Single Layer
Defects due to Coating -Multi-Layer
Defects in Interval between Coating and Drying
Defects due to Drying