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Innovative High-Speed Solvent-Free Polymer Coating Process

Learn about Sigma's Smart Coatings technology for wide web polymer coatings. Utilizing vacuum flash evaporation with radiation curing, this process offers high-speed, solvent/water-free deposition with unique surface functionalities. Discover the benefits, applications, and characteristics of this advanced coating method.

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Innovative High-Speed Solvent-Free Polymer Coating Process

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  1. High Speed Solvent-Free Process for Wide Web Polymer Coatings By Michael G. Mikhael Sigma Technologies International Inc. 10960 N. Stallard Pl. Tucson, AZ 85737 www.sigma-technologies.com SMART COATINGS, 2006 Surface Functionalization of Materials 1

  2. Plasma Treatment Equipment Vacuum Plasma Atmospheric Plasma Coating Equipment Flash Evaporation Polymer Coating Radiation Curing Physical Vapor Deposition Sputtering Technology Licensing Specialty Coated Products SIGMA’S PRODUCT MIX

  3. UNIQUE SURFACE FUNCTIONALIZATION TECHNOLOGIES

  4. Polymer Coating VACUUM POLYMER COATING

  5. Roll-to-Roll Wide Web Coating (up to 4 meters) The Process is Compatible with Inline Metal Evaporation and Sputtering Nanolayer Solvent/Water Free High Speed Deposition (up to 500 meter/min) Encapsulation of Individual Fibers without Blocking Porous Surfaces Smoothing and Leveling Effect Contained Process with no Environmental Impact Applying different Functionality on Both Sides of the Web (hydrophobic/hydrophilic) Inline Patterning for Polymer and Metal Coatings ADVANTAGES of POLYMER COATING in VACUUM

  6. FLASH EVAPORATION VACUUM POLYMER DEPOSITION WITH RADIATION CURING

  7. SCHEMATIC OF COATING SYSTEMS VACUUM POLYMER COATING CHAMBER VACUUM METALLIZING AND POLYMER COATING CHAMBER Plasma Treater Plasma Treater Monomer Evaporator Electron Beam Curtain Monomer Evaporator Electron Beam Curtain Monomer Evaporator Metallization Station Electron Beam Curtain

  8. Monomer Evaporation Why Flash Evaporation? Limitations Monomer Mw and vapor pressure Radiation curing chemistry (free radical and cationic) Critical Factors Size of the evaporator Equilibrium Between Evaporation and Condensation Monomer atomization Monomer feed rate POLYMER VACUUM COATING

  9. Overcomes the Problem of Solubility of Different Materials in Acrylate Binders No solubility limitation in the dye/binder formulation Perfect Molecular Level Dispersion in Vapor Phase Thin Liquid Deposited Layer Remains Homogeneous Cross Linking within Milliseconds from Deposition Freezes the Structure and Prevents Phase Separation More than 95% Chemical Utilization. ADVANTAGES OF THE FLASH EVAPORATION PROCESS

  10. Simple 100% Solids Chemistry Reduce materials inventory Greater flexibility Zero Negative Environmental Effects No reclamation requirements, water treatment, Reduced Plant Space Requirements 100m2 vs 350m2 Better Performance OTHER FACTORS

  11. Clear and Transparent Films Good Abrasion Resistance Coating Thickness ranges from 20nm to Several Microns High Temperature Polymers >250oC Unique Surface Leveling Properties Surface Energies from 20 dyne/cm2 to 75 dyne/cm2 Low Raw Material Cost CHARACTERISTICS OF ACRYLATE COATINGS

  12. VACUUM COATING AND CURING EQUIPMENTS

  13. 48” VACUUM COATING CHAMBER

  14. EQUIPMENTS: Sigma Has Sold Several Turn Key Coating Equipment for Different Applications

  15. APPLICATIONS:Pigmented colored coating Examples of High Chromophore Content in a Uniform Sub-Micron Coatings

  16. Examples of Small Molecules Organic Light Emitting Diodes (OLED) APPLICATIONS:Electroluminescence

  17. APPLICATIONS:Functional Coatings for Porous Materials, Paper, Fabrics and Non-woven Substrates Converting Non Woven PP Fabric to Teflon-Like Oil/Water Repelling Media Sigma Coated Oil and Water Repellant Oil Wetting and Water Repellant (control) Oil Water

  18. Sigma’s Coated Oil and Water Wetting Oil Wetting Water Repellant (control) Oil Water APPLICATIONS:Functional Coatings for Porous Materials, Paper, Fabrics and Non-woven Substrates Converting Non Woven PP Fabric to Paper-Like Water Transmitting Media

  19. Oil and Water Wetting (control) Sigma’s Coated Oil and Water Repellant Oil Water APPLICATIONS:Functional Coatings for Porous Materials, Paper, Fabrics and Non-woven Substrates Converting Rayon Fabric to Teflon-Like Oil/Water Repelling Media

  20. APPLICATIONS:Functional Coatings for Porous Materials, Paper, Fabrics and Non-woven Substrates Non Coated Fabric Coated Fabric Non-Woven Polypropylene Surface Functionalization with no Effect on Breathability

  21. APPLICATIONS:Leveling coating • Smooth leveling layer • Binding to ITO anode • Thermal / chemical resistance

  22. Moisture and Vapor barrier coatings Pigmented colored and color shift coatings Functional coatings for paper, fabrics and non-woven materials Selective coating on each side of the web Leveling coating Chemical resistance Chemical sensing Metal chelating Flame resistance coatings Release coatings APPLICATIONS FOR FLASH EVAPORATION VACUUM COATINGS

  23. Antibacterial coatings (Cl, Ag and QAC) Antireflection (low/high reflective index coatings) Polyelectrolyte thin film Low emissivity heat reflective coatings IR/RF coatings for signature control Metal Flakes (high aspect ratio) Controlled surface: Hydrophobic-oleophilic Hydrophobic-oleophobic Hydrophilic-oleophilic Alcohol resistant (Continued) APPLICATIONS FOR FLASH EVAPORATION VACUUM COATINGS

  24. Plasma and Coating Technologies THANK YOUAny Question?-----------------------------------------------------------------CONTACT INFORMATIONMichael G. MikhaelSigma Technologies Intl.10960 N. Stallard Pl., Tucson, AZ 85737520-575-8013mikh@sigmalabs.comwww.sigmalabs.com

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