Dr. Charles A. Bishop

Roll-to-Roll Vacuum Deposition Onto Flexible Substrates

Member Price: $899

Non-Member Price: $999

Dr. Charles A. Bishop 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.

Course Description

Roll-to-roll vacuum deposition only works well and reproducibly produces high quality products if the process is well understood and under control. This can only be achieved if everything is working as designed. In most systems this can be adversely affected by operators who may not appreciate how they may be affecting the process in how they interface with the system and process. 

This course is aimed at providing an overview of roll-to-roll vacuum deposition. There are different aspects to producing good vacuum deposited coatings. It requires a good vacuum combined with well controlled deposition sources depositing coatings onto equally well defined web surfaces. This course will help operators put each of these different aspects into context and help them to understand where and how improvements might be made. 

This course starts with a brief description what a vacuum is, the gauges and the pumps. Following this, process diagnostics and control, leak testing and troubleshooting are addressed. We will then move on to the substrates and relate the substrate quality to the coating quality. This will include the cleanliness of the surface of the substrates and how they can change with time and what can be done to modify the surface including pre-treatments and planarisation and post deposition coatings. This will be followed by looking at how the substrate needs to be managed through the deposition process where the heat load is frequently an issue. We will then look at the range of deposition sources that can be used which will include resistance heated evaporation sources, electron beam evaporation sources, magnetron sputtering and chemical vapour deposition with a brief resume of a number of other less often used sources. A number of the sources can be used as a metal source with a reactive gas added to allow compounds to be deposited by the reactive deposition process. This can be alumina deposited from the resistance heated evaporation sources in a simple metallizer through to reactive magnetron sputtering where the control of compound stoichiometry needs to be precise enough to control the conductivity of transparent conducting coatings. Other topics that will be mentioned are pattern metallization, system design considerations, including system cleaning and preparation, and hazards. This course is aimed at giving delegates a rounded view of most aspects of roll-to-roll vacuum coating.

Course Outline

1. Introduction & What is A Vacuum?

2. Vacuum Pressure Measurement

3. Pumping

4. Process and Coating Monitoring and Diagnostics

5. Leaks and Leak Testing

6. Vacuum Deposited Thin Film Products

7. Radiant and Resistive Heated Evaporation Sources

8. Other Deposition Sources

9. In-vacuum Pattern Deposition

10. Reactive Deposition

11. Web Substrates

12. Contamination, Cleaning and Pre-treatments of Web Substrates

13. Winding Webs In Vacuum

14. Pre-treatments and Effects

15. Hazards

16. Nucleation and Film Growth

17. Barrier - Introduction

18. Barrier - Products

19. Barrier - Basics and Measurements

20. Barrier - Materials

21. Barrier - Depositions and Defects

22. Barrier - Estimating Barrier Requirements and Structure

23. Coater Preparation & Troubleshooting