Coating Technologies and Techniques

In the laboratories and pilot plants the complete process chain for continuous coating can be represented, from material preparation via laboratory experiments through to continuous manufacture of rolled goods of variable material widths (20 – 75 cm) both from paste-like polymer systems of low viscosity and from thermoplastic polymer systems. Thus, a high degree of flexibility is given when selecting the suitable processing procedure. In the forefront of a product development both processing versions can be taken into consideration coequally.

For product-related developments upscaling to the pilot scale is part of the project. The advantages for the user on the one hand are the process parameters relevant for production gained this way, and on the other hand the model materials available as rolled goods in widths of up to 75 cm relevant for processing. For such developments preferably painting methods, depression, extrusion and calender techniques are used.

The technologies in our pilot plants are available for use by customers at any time. Our head of the plastics pilot plants will like to answer your questions concerning technological possibilities as well as concerning the test procedure.

Matthias Warnecke

Manager Plastics Technology Center

Laboratories and Pilot Plants

Coating based on systems of low viscosity

Coating based on systems of low viscosity

Techniques

  • Coater process doctor blade/roll as direct or reverse process, air doctor, rubber blanket doctor

  • Roll coating via reverse roll coater

  • Gravure printing using gravure rolls

  • Impregnation

  • UV drying/curing

  • Lamination before and after the drying tunnel

  • Infiltration

  • Sluicing

  • Coagulation

  • Hot air drying

  • Radio frequency drying

  • IR/UV drying

  • Embossing/polishing

  • Delamination

Technological possibilities

  • Operating width: max. 750 mm

  • Speed: up to a maximum of 20 m/min

  • Explosion protection operations are possible

  • IR drying/tempering before and after the drying tunnel

  • Convection drying with three drying zones up to 260 °C

  • HF module, heating plate, IR curing units, UV drying possible

  • Stenter frame with insertion automatic (spiked/clip chain or carpet)

  • Embossing and lamination unit up to a surface temperature of 200 °C

  • Cooling before the winding unit,

  • separately driven delamination and rewind unit

Extrusion coating based on the melt

Extrusion coating based on the melt

Techniques

  • Extrusion

  • Polishing

  • Lamination

Technological possibilities

  • Gravimetric and volumetric dosings

  • Different dies (flat sheet dies, strand dies)

  • Melt pump

  • Water quenches

  • Granulator

  • Polishing calender

  • Degasification with vacuum pumps (adjustable)

  • Single-screw and twin-screw extruder

  • Laboratory compounder

Calender coating based on the melt

Calender coating based on the melt

Walzenschmelzanlage

Techniques

  • Plasticizing

  • Blending

  • Haul-off

  • Duplicating

  • Lamination

  • Coating

  • Polishing, embossing

  • Gap load measuring

Technological possibilities

  • Operating width: max. 650 mm

  • Coating support: 30 – 2,000 g/m²

  • Operating speed: up to 30 m/min

  • Melt roll temperature: up to 250 °C

  • Gap load indication

  • different lamination or embossing rolls

Hotmelt lamination

Hotmelt lamination

Techniques

  • Manufacture of duplex and triplex laminates using thermoplastic and reactive hotmelt adhesive systems

  • Dot coating

  • Continuous coating

Technological possibilities

  • combined gravure and multiple-roll application head

  • Operating width: max. 500 mm stepless

  • Temperatures: exceeding 200 °C

  • large processing viscosity

Mass preparation system

Mass preparation system

Techniques

  • Dry-blend manufacture in the heating/cooling blender for

  • Particle crushing in mills

  • Blending and homogenising in the dissolver, paste blender and 3-roll grinding mill

  • Mechanical foaming using a rotor/stator system

  • Compounding in the extruder

  • Granulation

Innovative printing systems

Innovative printing systems

Techniques

  • Thermoplastic and hydroplastic processing for

  • 3D printed electronics

  • Imprinting of 3D objects

  • Printing of systems with high viscosity

  • Inkjet printing

  • Additive manufacture with individual and standard compounds

Technical Equipment

  • Piezo-clocked printing technology

  • High-viscosity printing head

  • Multiple-die inkjet printing head

  • Five-axis control for complex 3D printed components

  • Light beam sintering NIRDot

  • Available space: max. 189 mm x 134 mm x 230 mm

  • Processing up to a maximum of 300 °C

  • Layer thickness from 0.15 µm

Laser cutting and engraving

Laser cutting and engraving

Techniques

  • Cutting

  • Structuring/engraving

Technical Equipment

  • CO2 laser, 40 Watt

  • Working surface up to 1,016 x 711 mm

  • Resolution 75 to 1,200 dpi

  • Manual focus and autofocus


Contact

FILK - Forschungsinstitut für Leder und Kunststoffbahnen
Meißner Ring 1-5
09599 Freiberg

GERMANY

Fon: +49-(0)3731-366-0
Fax: +49-(0)3731-366-130
E-Mail: mailbox@filkfreiberg.de

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