13th International Coating Science and Technology Symposium
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SHORT COURSES
ISCST is planning to sponsor two short courses at the 2006 ISCST Symposium in Denver, Colorado. The short courses will be held on September 9 & 10, 2006 and the Symposium will be September 11-13, 2006.
Science & Technology of Coating and Drying Processes
September 9-10, 2006
Registration Fee: $995
Minimum registration to hold course: 15
Instructors: Dr. Edward D. Cohen (Consultant), Dr. Dennis J. Coyle (GE), Edgar B. Gutoff (Consultant), Prof. Wilhelm Schabel (U. Karlsruhe, Germany), and Dr. Steven Weinstein (Eastman Kodak)
• Practical Technology for Coating Processes
• Fluid Flow throughout the Coating Process
• Roll and Gravure Coating
• Premetered Coating Processes
• Detarying and Solidification of Coatings
The Role of Modeling & Visualization in the Coating Process
September 10, 2006
Registration Fee: $795
Minimum registration to hold course: 6
Instructors: Prof. Marcio Carvalho (PUC - Rio) and
Wieslaw Suszynski (Univ. Minnesota)
• Coating and Visualization Equipment
• Visualization Techniques
• Numerical Methods for Modeling Coating
• Experiments and Theory: Examples of Results
Science & Technology of Coating and Drying Processes
(Saturday & Sunday, September 9 & 10, 2006)
Approximate Schedule
Saturday September 9
7:30 Continental Breakfast
8:15 Opening Remarks (Cairncross)
8:45 - 12:00 Fluid Flow Throughout the Coating Process (Weinstein)
12:00 - 1:00 Lunch
1:00 - 4:00 Roll & Gravure Coating (Coyle)
4:00 - 5:30 Drying and Solidification (Schabel)
adjourn by 6:00 PM
Sunday September 10
7:30 Continental Breakfast
8:00 - 10 Drying and solidification (Schabel)
10 - 12 Premetered Coating Processes (Gutoff)
12 - 1 Lunch
1 - 2 Premetered Coating Processes (Gutoff)
2 - 5:30 Practical Technology for Coating Processes (Cohen)
adjourn by 5:30 PM
This course covers the science and technology of depositing liquid coatings on continuous webs and solidifying the coatings by drying and curing. The course will discuss principles related to the photographic, magnetic media, adhesive tape, converting, and other industries. The topics will range from descriptions and comparisons of processing equipment and coating techniques to discussions of the fundamental principles needed to analyze coating and drying processes. The course will cover the following topics:
Engineering Principles of Coating Flows
Steven J. Weinstein, Eastman Kodak Company
To understand the operating constraints and limitations of coating processes, one needs to have a firm understanding of fluid flows with liquid-liquid and air-liquid interfaces. Unfortunately, the mathematics of such flows is often quite complex, and this confounds our ability to physically understand the relatively basic underlying principles of interfacial flows and the effects of surface tension. The positive and detrimental effects of surface tension under dynamic conditions are often central to our ability to coat films of high uniformity. This section will introduce the practicing engineer to the qualitative physics of interfacial flows without mathematics, so that the engineer can understand the basis for the phenomena encountered in practice.
Roll Coating
Dennis J. Coyle, General Electric
This section covers the diverse technologies of roll coating, including forward roll, reverse-roll, squeeze-roll, and gravure coating. Particular attention is paid to the mechanisms by which the coating operation meters the fluid delivery, and instabilities in these flows such as ribbing and wave patterns. The emphasis is on a mechanistic understanding of the observed fluid flows.
Drying of Coatings
Wilhelm Schabel, Karlsruhe University
Drying and solidification are necessary steps in producing polymeric coatings from liquid solutions. The drying stage often controls the capacity and quality of the process, and improper choice of drying conditions can result in insufficiently dried coatings or various drying related defects. In order to design, control and optimize such processes, drying fundamentals should be taken into account properly. The first part of this course will review mechanisms and basic principles of heat and mass transfer in the drying process, dimensionless numbers, the Mollier diagram, thermodynamics and especially diffusion in the film. Key topics of the second part of this section will include fundamentals, recent developments and pertinent literature about drying of solvent and water based coatings, optimizing of drying parameters, new measuring techniques, impinging nozzles, coating defects, numerical simulation of technical dryers, industrial case studies, multicomponent diffusion.
Premetered Coating
Edgar B. Gutoff, Consultant
Premetered coating means die coating, as in slot, slide, and curtain coating. Assuming proper operation, the flow rate to the coating die can be accurately set to produce a desired coating thickness for a known coating width and coating speed. This section covers these coating methods, and includes slot coating against tensioned web, the use of bead vacuum, the limits of coatability for each of these methods, coating defects and their avoidance, surface tension effects on coating, electrostatics effects, and the effect of surface roughness on the coatability limits.
o Practical Technology for Coating Process
Edward D. Cohen, Ed Cohen Consulting
The successful operation of a web coating process requires the practical utilization of a wide variety of technologies and competencies, in addition to the basic processes of coating, drying and web handling. This section will discuss several of these practical technologies. Topics to be covered include: current trends in the converting industry and guidelines to selecting the correct method based on product requirements; scale-up procedures and the role of laboratory and pilot coaters to develop the final process; coating defects, which adversely affect product performance and profitability, technology to detect, characterize and eliminate these defects; and the basic factors need to insure successful process.
Who should attend:
This course is designed for coating engineers, formulation scientists, managers and manufacturing personnel who are interested in gaining a deeper understanding of the principles of fluid distribution, deposition, and solidification in coating processes.
Instructor Biographies:
Dr. Edward D. Cohen (Consultant)
Edward Cohen is a technical consultant in all aspects of the web coating process. He received Ph.D from the University of Delaware and B.S.Ch.E. from Tufts University. His expertise is in the coating and drying of thin films, coating process development and scale-up, polyester base development, film defect mechanisms and defect characterization techniques. He has over 40 years experience in coating research and manufacturing technology. He recently retired from DuPont Central Research and Development as a DuPont Fellow. Cohen is co-editor of Modern Coating and Drying Technology and co-author of Coating and Drying Defects: Troubleshooting Operating Problems and many technical publications. He is Technical Consultant for AIMCAL, Treasurer of the ISCST, and is a contributing author for Converting Magazine, and Paper Film & Foil Converter. He received the John Tallmadge Award for Contributions to Coating technology and the AIMCAL President's award for meritorious service to AIMCAL and the Converting Industry.
Dr. Dennis J. Coyle (General Electric)
Dr Coyle is currently at General Electric Global research in Niskayuna, NY, where he manages the Advanced Optical Films group, specializing in polymer processing and coating. He is active in both R&D and Manufacturing implementation. He also spent two years as manager of the Solvent Coating Research group at Eastman Kodak in Rochester NY. He earned his Ph.D. in Chemical Engineering from the University of Minnesota in 1984 with his thesis on “The Fluid Dynamics of Roll Coating.” In 1998 he received the “Young Investigator Award” from the ISCST. Dr. Coyle holds 8 US patents and has authored three book chapters and 20 publications on coating processes.
Dr. Edgar B. Gutoff (Consultant)
Edgar B. Gutoff, a consultant on coating and drying, organized the first Coating Symposium in 1982, was the founding Secretary of the ISCST, has organized a number of coating courses and seminars, and has co-authored "Coating and Drying Defects" and "Modern Coating and Drying Technology". In 1994 he received the John A. Tallmadge Award of the AIChE for Contributions to Coating Technology. He is a Fellow of the AIChE and of the IS&T. He had worked at Polaroid for 28 years, and is an Adjunct Professor at Northeastern University.
Dr. Wilhelm Schabel (Karlsruhe University)
Dr. Schabel is head of a research group investigating the drying of coatings and mass transfer in thin films with fundamental and industrial applications. He received his Ph.D. (with honors) from Karlsruhe University (TH) in 2004. His thesis is entitled “Drying of Polymer Films - Measurements of Concentration Profiles by means of Inverse Micro Raman Spectroscopy (IMRS)”. Dr. Schabel has carried on these studies with the help of interim four Ph.D. students. The research activities in his group cover new measurement techniques, fundamentals of film formation and diffusion and numerical simulation tools for industrial drying applications. He is currently a lecturer at the Institute of Thermal Process Engineering in Karlsruhe, an old and well-recognized institute where Chemical Engineering was founded in Germany. Dr. Schabel is one of the authors of the VDI-Wärmeatlas, 10th ed. (2006) and has published more than ten articles and several congress contributions on drying of coating processes.
Dr. Steven J. Weinstein (Kodak)
Steve has worked for Eastman Kodak Company for 18 years after receiving his PhD in Chemical Engineering from the University of Pennsylvania in 1988. His areas of expertise are interfacial fluid mechanics, transport phenomena, and applied mathematics. Steve has published over 25 refereed articles in the field of coating, including thin film flows, die design, wave stability, curtain flows, and web dynamics, and has 7 patents in these areas. He has co-authored a book chapter on capillary hyrdrodynamics and interfacial phenomena in “Liquid Film Coating” edited by S. F. Kistler and P. M. Schweizer, and recently co-authored an invited review article on Coating Flows in Vol. 36 (2004) of Annual Reviews of Fluid Mechanics. Steve has won the CEK Mees award for excellence in research and technical writing, the highest research award bestowed by Eastman Kodak Company, and was recipient of the ISCST Young Investigator Award in 2000. Currently, in addition to his work at Kodak, he is an Adjunct Professor of Chemical Engineering at both the University of Rochester and Cornell University, and is teaching the core graduate course on fluid dynamics at the University of Rochester.
The Role of Modeling & Visualization in the Coating Process
(Sunday, September 10, 2006)
Coating industry today often requires production improvements and quick development of new products. Ever thinner liquid layers are now more frequently applied to substrates as multilayer coatings at tighter thickness tolerances and at ever higher line speeds, and with less production waste. Complete understanding of the different processes help coating professionals to meet the product development and production challenges they face every day. It is important to analyze the physical mechanisms that determine the success or failure of a process. Flow visualization and computer aided modeling are priceless tools available to coating professionals today. This course will discuss methods, techniques and modern equipment developed at the University ofMinnesota (Minneapolis), Pontificia Universidade Catolica (Rio de Janeiro) and other places, used in successful visualization and modeling of roll, slot, slide, curtain, and other types of coating techniques. . The ways how both of these approaches (experimental and theoretical) interact and complement each other and lead to better process understanding will also be presented by means of several examples.
Approximate Schedule
Sunday September 10
7:30 Continental Breakfast
8:00 Opening Remarks (Cairncross)
8:15 - 12:00 Visualization of Coating Processes
12:00 - 1:00 Lunch
1:00 - 5:30 Numerical Modeling of Coating Processes
adjourn by 5:30 PM
Topics:
Coating lab - setting-up for visualization
Coating and Visualization Equipment - proper design and selection
Visualization techniques
Basic equations
Numerical methods
Experiments and theory, examples of results in:
- single and multilayer slot, slide and curtain coating
- tensioned web over slot coating
- roll coating instabilities: ribbing, misting
- gravure, blade and other coating methods
Who should attend:
This course is designed for coating engineers and scientists dedicated to improving existing coating process or developing new ones, and their managers.
Instructor Biographies:
Professor Marcio Carvalho (Pontificia Universidade Catolica do Rio de Janeiro)
Prof. Marcio Carvalho received his Ph.D. in Chemical Engineering from the University of Minnesota in 1995, with a thesis on roll coating process with deformable rolls. He worked as a Senior Process Development Engineer with 3M Company and Imation Corporation in the areas of pre-metered coating, roll coating and drying technologies. He is now an Associate Professor at the Department of Mechanical Engineering at Pontificia Universidade Catolica do Rio de Janeiro, in Brazil, where he leads a research program on fluid mechanics and rheology of industrial processes. He has authored several papers and patents related to coating and drying technologies.
Wieslaw J. Suszynski (University of Minnesota)
Wieslaw J. Suszynski is the Research Engineer in charge of the Coating Process Fundamentals Laboratory at the University of Minnesota. He is responsible for the design and operation of the experimental coating equipment and associated instrumentation as well as scientific visualization, photography, standard and high-speed video imaging. He has participated in the development of coating and drying visualization technology in the Coating Process Fundamentals Program for more than 17 years since its early stages. He has done work within the University and in collaboration with several Member Companies of the Interfacial and Materials Research Center. He graduated from the Cracow University of Technology, Poland, where he received his MSChE degree.