AIMCAL Europe 2012 Short Courses (optional)

How Substrate Quality and Cleanliness Affects Roll-to-roll Vacuum Deposition

Dr. Charles Bishop, C.A. Bishop Consulting Ltd.

As with most processes the quality of the input directly affects the output. In this course we will follow the substrate through the roll-to-roll coating process. It starts by looking at what can vary on the incoming substrate how this can affect end products. The substrates can be modified between manufacture and being put into the vacuum system and we will look at what can be modified and what benefits this can give the substrates. We will then look at how the substrate surface can be changed and what effect this has on the nucleation, growth and properties of the coating. Finally we will then look at how the substrate can interact with the web winding and the heat load that the substrate will be exposed to during the deposition process.

Understanding how the substrate affects and interacts with the vacuum deposition process is equally applicable to most, if not all, coatings from simple metalizing through to ultra-barriers, transparent conducting coatings or photovoltaics.

Charles Bishop, after a varied career with Imperial Chemical Industries, elected to return to consultancy work in 1998. He established his own business, C.A.Bishop Consulting Ltd., offering help on all aspects of vacuum deposition including system design, process development and scale-up, process control, plasma surface treatments and coatings, as well as troubleshooting existing processes and running training courses. Charles has published over 60 technical papers, has 5 patents and has conducted training courses in the UK, USA, India and Europe. In 2007 his book Vacuum Deposition onto Webs, Films & Foils was published and this was followed in 2010 by a second book Roll-to-roll vacuum deposition of barrier coatings.

A Practical Approach to Eliminate Web Wrinkling

Timothy J. Walker - TJWalker+Associates, Inc.
Dr. Dilwyn P. Jones - Emral Ltd.
Dr. David R. Roisum - Finishing Technologies

Wrinkles and creases are a major waste category in many converting operations. Wrinkling of paper webs causes an even worse problem -- web breaks. And wrinkles are on the rise. Many converting industry trends mean there are even more wrinkles coming your way. Are you...

• Moving to more polymer film products?
• Decreasing your web thickness?
• Increasing web width?
• Running faster and more integrated processes?

This half-day seminar will present the key concepts, including material, equipment, and process conditions that promote or reduce web wrinkling. Questions that will be answered in this seminar:

• What are the four mechanisms that create wrinkles?
• Which wrinkles are well modeled and what can the models teach us?
• How can wrinkles be prevented with web line geometry and standard cylindrical rollers?
• How does your web react to roller misalignment and diameter variations and how are these used to prevent wrinkles?
• How do special anti-wrinkle rollers work and when are they appropriate based on wrinkle cause, web tension, web width, and environment?

Timothy J. Walker is a web handling, winding, laminating, and slitting specialist with 25 years experience in process development, production support, and technical education. He is president of TJWalker+Associates Inc, providing services in web-based processes and technology management. Tim estimates over 4000 people have attended his web handling training over the years, mostly in private on-site classes. Before starting his own company in 1999, Tim was corporate web handling technology leader for 3M, leading 3M’s web handling process development lab and their corporate process technology management committee. Tim served for many years on the Industrial Advisory Board at Oklahoma State University’s Web Handling Research Center and co-taught their “Application Seminar on Web Handling” course.

Dilwyn Jones is a Consultant in Materials Science and Engineering, working through his company Emral Ltd based in the North East of England. He graduated from the University of Cambridge with First Class Honours in Natural Sciences, and stayed on to complete a PhD in Low Temperature Physics. He then joined ICI (Imperial Chemical Industries) where he worked on the processing and properties of polymers at their laboratories in Welwyn Garden City and Wilton, and during secondments to Cranfield Institute of Technology and the ICI production facility at Hopewell, Virginia. He moved to DuPont in 1998, along with ICI’s Polyester Film business. He set up his consultancy business in 2000, and works with clients worldwide on web handling, polymer processing and properties, static charge, training, software development and Finite Element Analysis, bringing a blend of fundamental understanding, modelling and practical application.

David Roisum of Finishing Technologies is a well-known authority in web handling and converting. He has authored eight books and more than 100 papers and articles such as his monthly Web Works column in Converting magazine. His background includes a variety of web manufacturing and converting experiences. At Beloit Corp. he was a machine designer and then research manager for winders. At the Web Handling Research Center he served as an advisor and helped set up their pilot lab. At Kimberly-Clark he worked as an internal converting consultant to all business units. Finally, as an independent consultant, he helps troubleshoot a variety of problems in the paper, film, foil, nonwoven and textile industries. He has visited nearly 1,000 plants in his more than 30 years of experience. An accomplished professional speaker and instructor, he is noted for his skill in translating highly technical information into a common sense, practical reference. He has been honored several times with TAPPI's Finest Faculty Award based on the positive feedback from short course attendees. More than 5,000 students have attended his own courses including the ever-popular Web Handling and Converting.

Winding: Equipment, Mechanics, and Roll Quality

Timothy J. Walker - TJWalker+Associates, Inc.
Dr. Dilwyn P. Jones - Emral Ltd.
Dr. David R. Roisum - Finishing Technologies

Winding is, for many, an area of great waste, delay, customer complaint and troubleshooting effort. Yet, some or much of this is avoidable if you apply the art and science that has already been learned about winding. Three of the leading web-handling experts team up to share their cumulative experience that totals nearly one century. Here you will find a tightly integrated school that takes you from basics, to theory and to defect reduction in a single afternoon. The cost of this school will be more than repaid by eliminating but a single customer complaint or ineffective troubleshooting effort.

Part 1 - Equipment: Understanding Winders - by Timothy J. Walker

• What is the difference between center vs. surface winders? Nipped vs. gapped winders?
• What is taper tension and winder oscillation? Why are they used?
• When are winding rolls sensitive to good or bad roll starts?

Part 2 - Mechanics: Understanding the Winding Process - by Dilwyn P. Jones

• How does a roll build, and what software is available to model it?
• When does entrained air become significant in winding and how is it managed?
• What determines a roll's structure during and after winding?

Part 3 - Roll Quality: Using Mechanics to Eliminate Common Roll Defects - by David R. Roisum

• What are the sources and remedies of shifted layers in winding?
• Why do buckling form in wound rolls?
• How are web bagginess and winding related?