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TRANSMACH Résumé de rapport

Project ID: G1RD-CT-2000-00334
Financé au titre de: FP5-GROWTH
Pays: Greece

Integrated LAV machine (with incorporated UFMWE monitoring units, managed by a LAN) showing intelligent and highly reliable in-line control beyond existing standards in monitoring of the LAV

A LAN was designed and constructed for controlling the UFMWE unit. The ellipsometric measurement and modeling calculation of the coated layer is carried out by the UFMWE and the set of layer relevant data (e.g., calculated thickness) and status data (e.g., error codes) is sent to the network of the coating machine (PLC, EB gun control system). For the closed loop PID control of the thickness, the web-speed or EB power will be controlled. For other layer parameters other machine parameters can be used for control purposes. The UFMWE unit installed on a lab scale coater was further tested and improved. A final version of DP2 software was installed and checked in order to verify the ability of controlling the EB deposition processes. Afterwards, the system was installed on the LAV machine (coater).SiOx coatings were EBE deposited on PET substrates using as evaporated source material the standard SiO18, which showed the best barrier properties measured after retortability tests. The first point of interest was to investigate the accuracy in thickness calculation by altering the web speed. A correlation formula has been established between web speed and resulting SiOx coating thickness, by applying the standard deposition conditions. However, upon the installation of the UFMWE unit on the coater, this correlation is no longer fully valid due to the alterations that need to be done in the deposition processes.

The parameters tested and monitored within this task were:
- Thickness
- Optical properties
- The accuracy in the modelling procedure applied when during the deposition process
- It was attempted to investigate the effect of the in vacuum and in air oxidation of the deposited SiOx layers.

The accuracy in the modeling procedures, the initial fitting parameters as well as the acquisition parameters set in the recipe mode were tested.

The adaptation of the UFMWE unit to LAV machine was installed in the part were the pretreatment procedure was performed on the PET web prior the SiOx barrier coating deposition. Also, due to the position of the UFMWE, it was necessary to run the appropriate pretreatment of the PET membrane and the EBE deposition processes in a non-standard mode. As a result, two main points emerged showing that the whole barrier coating deposition process is not optimal. First, there is a time delay between the pretreatment and the coating deposition, which may cause adhesion failures of the SiOx coatings on the PET. Second, the quality of the initially deposited SiOx layers is not optimal due to the reverse running mode of the EBE, and thus the initial layers of the SiOx coatings deposited on PET have different composition and stoichiometry properties. It is very possible that these layers have a considerably lower density than the bulk of the SiOx coatings.

All these factors resulted in poorer barrier properties than the SiOx films produced and characterised by TransMach. As a consequence, it was considered more meaningful to work on the optimisation of the barrier coating deposition processes, using UFMWE controlling, in the technical scale EBE coater at AF. Representative results on these activities are presented in the final report of the project.

Informations connexes


Stergios LOGOTHETIDIS, (Project Coordinator)
Tél.: +30-2310998174
Fax: +30-2310998039