contact cleaning for functional coatings in … 2012/contact cle… · 1: 2. 3: soft. 2.169....
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AIMCAL 2012 1
CONTACT CLEANING FOR FUNCTIONAL COATINGS IN EMERGING TECHNOLOGIES
Sheila Hamilton Teknek Ltd
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AIMCAL 2012 2
OUTLINE
• Historical view of contact cleaning • Current market Drivers • Science of adhesion • Surface roughness analysis • Adhesion measurements • Other results • Conclusions
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AIMCAL 2012 3
CLEANING FUNDAMENTALS
• Adhesive force between the elastomer roller and the particle must be greater than the force between the particle and the substrate
• The adhesive force between the particle and the adhesive must be greater than that between the elastomer roller and the particle
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AIMCAL 2012 4
HISTORICAL VIEW
• Softer rollers have greater contact area • Softer rollers clean better • Soft rollers deform around particles • Glossy rollers are smooth • Smooth rollers clean better
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AIMCAL 2012 5
MARKET DRIVERS
• Thinner films • Increased processing of sheets • Specialist functional coatings • Structured films eg prism films • Static generative materials • Unbalanced surfaces
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AIMCAL 2012 6
SHORE HARDNESS
0
10
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80
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Holding capacity
Shore
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AIMCAL 2012 7
INTERFACIAL FORCES
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AIMCAL 2012 8
EXAMPLES OF ADHESION FORCES
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AIMCAL 2012 9
MACRO ADHESION
RUBBER COPPER STEEL Cu/KAPTON POLYESTER POLYCARBONATE
(Gloss) (Matt)
SOFT 1.17 3.26 0.51 2.55 2.37
PANEL 1.49 3.32 0.81 2.63 1.07
FILM 0.63 0.81 0.34 1.68 1.4
F3 0.11 0.11 0.11 0.05 0.12
NANO 0.08 0.04 0.07 0.75 0.34
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AIMCAL 2012 10
CONTACT AREA
Contact area is impacted by • Roller surface roughness • Pressure • Shore hardness • Particle morphology
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AIMCAL 2012 11
SURFACE ROUGHNESS Scan Size Sample name
1 2 3
Soft 2.169 11.143 38.582
Panel 7.355 13.493 23.467
Nanoclean 3.616 1.400 6.292
Film 7.453 16.861 18.54
F3 31.009 49.085 98.334
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AIMCAL 2012 12
SURFACE OF SOFT ELASTOMER
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AIMCAL 2012 13
SURFACE OF PANEL ELASTOMER
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AIMCAL 2012 14
SURFACE OF F3 ELASTOMER
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AIMCAL 2012 15
SURFACE OF NANOCLEEN ELASTOMER
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AIMCAL 2012 16
SURFACE ROUGHNESS
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AIMCAL 2012 17
SUMMARY
• For small particles surface roughness has to be considered on a microscopic scale
• Ideally surface asperities should be matched to the size of the particle of contamination
• The flexibility of the roughness peaks is important.
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AIMCAL 2012 18
FORCE DISPLACEMENT CURVES
• Gold
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AIMCAL 2012 19
FORCE DISPLACEMENT CURVES
• Polystyrene
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AIMCAL 2012 20
FORCE DISPLACEMENT CURVES
• Silica
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AIMCAL 2012 21
ADHESION FORCES Type of Probe Sample name
Silica Gold-coated silica Polystyrene
Soft 752.08±147.06 951.87±69.48 1027.79±109.82
Panel 848.11±112.98 823.55±160.72 847.12±214.75
Nanoclean 803.08±443.79 285.14±161.34 1073.17±629.94
Film 866.80±144.75 1152.12±125.74 1177.89±81.77
F3 1076.98±420.92 746.64±329.49 813.09±393.31
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AIMCAL 2012 22
ADHESION FORCES
• Panel and soft and film
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AIMCAL 2012 23
ADHESION FORCES
• F3 and Nanocleen
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AIMCAL 2012 24
SUMMARY
• Hydrophobicity of materials is important for adhesion
• Adhesion on the macro scale does not relate to the micro scale
• Surface roughness on a micro scale causes variations in the adhesion forces
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AIMCAL 2012 25
CONCLUSIONS
• Moisture affects cleaning performance • Good cleaning improves wettability • Lot more experimentation required
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AIMCAL 2012 26
ACKNOWLEDGEMENTS
• Dr Zhenyu (Jason) Zhang and Professor Mark Geoghegan of the Polymer Institute at The University of Sheffield for help with the testing.