Nordson Polymer Processing Systems
Slide Curtain Die Technology
what you need to know
Topics
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
2 |June 2016
End Markets: Consumer Non-Durables, Durables, Technology
….Every Day You Experience the Value We Bring
Flexible Packaging
Rigid Packaging
Disposable Hygiene
Appliances
Electronics
Displays
Automotive
Paper
Battery
Construction
Solar
Tape & Label
Other Markets - Agriculture, Furniture, Industrial, LEDs, Containers, Aerospace
Nordson’s Current and Potential Curtain Coating Markets
3 |June 2016
Coating Technologies
Curtain & Slide
Curtain Coating
4 |June 2016
Coating Technology Overview
Min
Max
Viscosit Viscosit
y cPs
y cPs
Technology
Premetered
Slot Die Fixed lip*
1
175,000
Slot Die Adjustable Lip*
1
250,000
Tension web slot*
1
100
Multi-layer cascade*
1
500
Curtain*
5
500
Self Metered Roll Coating
Forward Roll
20
2,000
Reverse Roll
200
40,000
Dip
40
1,500
Multi Roll forward
30
500
Comma
1000
300,000
Self - Metered Doctored Roll Coaters
Gravure direct forward
30
2,000
Gravure direct reverse
20
13,000
Gravure direct chamber
10
2,000
Mayer Rod
50
1,000
Air Knife metering
1
500
Air Knife squeegee
5
500
Knife over roll
100
50,000
Blade
500
40,000
Dip & scrape
25
500
Specialty Methods
Spray
10
30000
Screen Printing
50
1500
Micro Gravure
1
4000
Min Line
Speed
fpm
Max Line
Speed
Min Wet Max Wet Coating
fpm
Thick µm Thick µm Uniformity
Required
Expertis
#
Patch
e
Layers coat Cost
0.5
0.5
20
20
400
2000
2000
3200
1000
3000
<10
12
1
25
5
3810
2500
50
250
500
1-2%
1.75-3.50%
2%
2%
2%
3
3
3
18
18
Y
Y
N
Lanes
Lanes
High
High
High
High
High
Low
Med
Med
High
High
100
20
45
100
1500
1150
600
2000
10
14
10
0.15
200
500
150
4
10%
2%
10%
10%
10%
1
1
1
1
1
N
N
N
N
N
Low
Med
Low
High
Low
Low
Med
Low
High
Low
25
10
25
10
40
125
8
350
50
2300
1000
2300
1000
400
2000
400
5000
600
3
3
1
4
0.1
10
26
10
5
65
206
75
80
200
50
750
750
250
2%
2%
2%
10%
5%
5%
8%
10%
10%
1
1
1
1
1
1
1
1
1
Y
Y
Y
N
N
N
N
N
N
Low
Med
Med
Low
Low
Low
Low
Low
Low
Low
Med
Med
Low
Low
Low
Low
Low
Low
50
0.7
8
400
20
500
50
10
1
340
500
500
10%
100%
2%
1
1
1
Y*
Y
Y
High
Low
Low
High
Low
Low
Different literatures are indicating different values of parameters and performances so
displayed numbers may vary with your data and experience
5 |June 2016
Coating Parameters
Coating Processes
•Coating Accuracy
•Layer Thickness
•Single Layer
•Multiple Layer
•Stripe Coating
•Transfer Coating
•Direct Coating
•Coating Systems
•Substrate Speed
Coating Chemistry
•Rheology
•Viscosity
•Solid Content
•Type of Solvent
•Adhesion/Cohesion
•Shear ratio
•Pigmented
•Surface tension
Pretreatment
•Corona
•Plasma
•Cleaning
Substrate
•Surface energy
•Roughness
•Surface Structure
•Contact angle
•Web stability
Environment
•Humidity
•Temperature
•Inert Conditions
6 |June 2016
Drying/Curing
Finishing
•Calandering
•Embossing
•Slitting
•Convection Drying
•Contact Drying
•Infrared Drying
•Sintering
•NIR
•High Frequency
•UV-Crosslinking
•EBeam
Coating principles
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, Vw
the substrate velocity, h the height/thickness and b the width of the applied
layer.
7 |June 2016
Coating Technology Comparison
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 selfmetered 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.
8| |
Coating Technology Comparison
Min
Max
Viscosit Viscosit
y cPs
y cPs
Technology
Premetered
Slot Die Fixed lip*
1
175,000
Slot Die Adjustable Lip*
1
250,000
Tension web slot*
1
100
Multi-layer cascade*
1
500
Curtain*
5
500
Self Metered Roll Coating
Forward Roll
20
2,000
Reverse Roll
200
40,000
Dip
40
1,500
Multi Roll forward
30
500
Comma
1000
300,000
Self - Metered Doctored Roll Coaters
Gravure direct forward
30
2,000
Gravure direct reverse
20
13,000
Gravure direct chamber
10
2,000
Mayer Rod
50
1,000
Air Knife metering
1
500
Air Knife squeegee
5
500
Knife over roll
100
50,000
Blade
500
40,000
Dip & scrape
25
500
Specialty Methods
Spray
10
30000
Screen Printing
50
1500
Micro Gravure
1
4000
Min Line
Speed
fpm
Max Line
Speed
Min Wet Max Wet Coating
fpm
Thick µm Thick µm Uniformity
Required
Expertis
#
Patch
e
Layers coat Cost
0.5
0.5
20
20
400
2000
2000
3200
1000
3000
<10
12
1
25
5
3810
2500
50
250
500
1-2%
1.75-3.50%
2%
2%
2%
3
3
3
18
18
Y
Y
N
Lanes
Lanes
High
High
High
High
High
Low
Med
Med
High
High
100
20
45
100
1500
1150
600
2000
10
14
10
0.15
200
500
150
4
10%
2%
10%
10%
10%
1
1
1
1
1
N
N
N
N
N
Low
Med
Low
High
Low
Low
Med
Low
High
Low
25
10
25
10
40
125
8
350
50
2300
1000
2300
1000
400
2000
400
5000
600
3
3
1
4
0.1
10
26
10
5
65
206
75
80
200
50
750
750
250
2%
2%
2%
10%
5%
5%
8%
10%
10%
1
1
1
1
1
1
1
1
1
Y
Y
Y
N
N
N
N
N
N
Low
Med
Med
Low
Low
Low
Low
Low
Low
Low
Med
Med
Low
Low
Low
Low
Low
Low
50
0.7
8
400
20
500
50
10
1
340
500
500
10%
100%
2%
1
1
1
Y*
Y
Y
High
Low
Low
High
Low
Low
Different literatures are indicating different values of parameters and performances so
displayed numbers may vary with your data and experience
9 |June 2016
Coating Technology Comparison
Coating Technology Comparison
viscosity range
line speed
thickness
10
B
C
A
9
A
F
8
G
7
D
E
J
B
6
I
D
D
H
5
E
J
I
G
4
C
G
H
J
3
J
H
F
2
F
I
E
1
H
10 - 5000 cps
9
10
4
200 - 40000 cps
20 - 13000 cps
10 - 2000 cps
100 - 50000 cps
Slot Die Fixed Lip
1 -175000 cps
Slot Die Adjustable Lip
1 -250000 cps
Curtain Slide Die
C
Ranking
1 - 3000 µm
100 - 1800 m/min
7
5 - 350 m/min
5
2
8
1
2 - 350m/min
8 - 750m/min
2 - 150m/min
0,5 - 600 m/min
D E F
A
B
D E F G H I
I
Ranking
J
Ranking
Summary
18
9
9
10
45
43
43
8
1
8
35
1
1
1
5%
8
8
5
6
1
8
8
8
8
30
30
33
22
2%
10%
8
4
1
1
8
8
29
27
2 - 4%
1 - 2000 µm
10
9
9
6
14 - 500 µm
7
9
4
3
3- 20 µm
1 - 75 µm
26 - 750 µm
2
5
50 - 340 µm
1 - 2000 µm
C
A
Ranking
8
8
10
0,5 - 600 m/min
number layers
C
G
A
Ranking
Pre-metered
A
B
C
B
B
coating uniformity
1%
9
7
10
6
2%
2
3
8
4
2%
2%
8%
5
7
2%
3
3
Self-metered Roll Coating
D
Reverse Roll Coating
Self-metered Doctor Roll-Coater
E
F
G
H
Gravure Direct Reverse
Gravure Direct Chamber
Knife Over Roll
Air Knife Metering
1 - 500 cps
15 - 150m/min
1 - 200 µm
Specialty Coating
I
J
Spray
Micro Gravure Coating
10 |June 2016
10 - 30000 cps
1 - 4000 cps
6
3
20 - 150m/min
1 - 250m/min
1 - 500 µm
Technology based decision process can determine top 3 options that need to
be
evaluated for the performance vs. cost to make final decision
Coating Technology Comparison, Conclusion
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?
11 |June 2016
Slide Curtain Die Technology
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
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
Slide Curtain Die Technology
•
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
Fluid Delivery System
•Viscosity
•Solid content
•Bubble-free
•Pulse-free
Slide Curtain Die
•Manifold design
•Slot gap tolerance
•Lip inserts
Edge-Guide
Impingement Zone
•Air boundary layer
•Vacuum
Web- Flow /Speed
•Web-wind
•Constant speed
•Pulse-free
15 |June 2016
•Length
•Water port
•Vacuum port
•Neck-in,edge-bead
Slide Curtain Die Technology
Manifold Design, Flatness and Gap Tolerance
µm
LOW
HIGH
DIFF
16 |June 2016
A
B
C
-0.334819 -0.554183 -0.219364
D
-0.069273
E
-0.037523
0.115455
0.000000
0.496456
0.935184
0.871684
0.450274
0.554183
0.715820
1.004457
0.909206
Slide Curtain Die Technology
Single or Multiple Layer Design
•Endplate with edge-guide integration for
different length
•Possible deckling or application width
adjustments
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
Minimized Neck-in, No Edge-bead
•Distance of edge-guide to substrate
•Liquid gas interface
•Liquid solid interface
•Dynamic contact line
17 |June 2016
Slide Curtain Die Technology
Capabilities Matrix
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
18 |June 2016
Slide Curtain Die Technology, Feedback
Curtain vs. Air Knife Coater, PaperCon 2011 Northern Kentucky Convention Center
•
Superior coverage and clearly reduced
cloudiness
•
Best coating color distribution (CD & MD)
•
Improved visual appearance by coating
layer
•
Significant higher solid content (62-64%)
•
No speed limit ( >> 500m/min)
•
Wide coat weight range (11 to 20 gsm
without any difficulty)
•
Very good runnability (no web break
during curtain coater use since start-up)
•
Furnish cost reduced
•
Production increased due to increase
machine speed
•
Energy savings due to increased solid
content 42% - 62%
•
Coating cost reduction(reduced
pigment cost at maintained quality due
to superior coverage
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 coating
coverage
19 |June 2016
Slide Curtain Die Technology, Feedback
Curtain vs. Gravure, AIMCAL 2012
20 |June 2016
Slide Curtain Die Technology, Summary
•
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 is a Green Technology
21 |June 2016
Nordson Polymer Processing Systems
Slide Curtain Coating Dies
within Fluid Coating Application Systems