2D Web Coating Simulator Software

Transcription

1 2D Web Coating Simulator Software Israel Tartakovsky 4S Scientific Ltd. Kiryat Gat, Israel Daniel Feinman Acktar Ltd. Kiryat Gat, Israel

2 Introduction The WCS software is a two-dimensional simulation model developed for Vacuum web coaters. The scope of this model is to assist in: Process design. Conceptual machine design. Winding considerations. Identification of the dominating system parameters 4S Scientific 2

3 Introduction Material properties Coating Substrate Process parameters Technique source properties coating properties Machine configuration Physical construction Thermal properties 2D thermal profiling 2D deposition profiling On-line control tools 4S Scientific 3

4 Starting the WCS application 4S Scientific 4

5 Reviewing and changing parameter settings 4S Scientific 5

6 Source arrangement and parameters 4S Scientific 6

7 Process zone winding arrangement 4S Scientific 7

8 Simulation results The following simulation results including detailed information on the coating process are displayed on the screen: Heat load characteristics Two-dimensional thermal field Temperature profile in MD Coating thickness distribution Simulation results may be saved to a text file for future reference and analysis. 4S Scientific 8

9 Heat load - Metallizing example Web width: 500 mm 5 boats Evap. rate: 6 g/min per boat Full heat load Radiation heat load 4S Scientific 9

10 Thermal field - Metallizing example 4S Scientific 10

11 Temperature profile (Machine Direction) 4S Scientific 11

12 Coating thickness profile 4S Scientific 12

13 Example - Free span coating of thin metal foils 4S Scientific 13

14 Fields of application Electrodes (Batteries / Capacitors) Flexible solar cells Packaging products Solar Control film Magnetic storage media Anti-Corrosion coatings Optical multi-layers 4S Scientific 14

15 Benefits to Vendors Coating machine vendors can use the simulator to optimize the design of the machine planned or commissioned to be built. The simulator enables the vendor to visualize how changes in machine design may affect the process and final product characteristics. For example, the simulator predicts the temperature at which the web material leaves the deposition zone. Two-dimensional simulation can assist in selecting a source design to achieve coating uniformity, thereby optimizing product quality and coating material collection. Among other advantages WCS allows vendors to considerably accelerate the design decisions together with the customer in the of concept development phase. 4S Scientific 15

16 Benefits to Coating Manufacturers Coating manufacturers can use the software to simulate conditions required to run the coating process efficiently, thereby saving time and expense of trial runs. Two-dimensional simulation allows witnessing the effect of changes in process parameters on heat load and temperature distribution in machine and crossmachine directions and on coating uniformity. Coating manufacturers can also use the simulator to train process engineers and operators without risking damage to the real machine. 4S Scientific 16

17 Modeling background ρ c Here: T t = κ ΔT + g( x vt, y, z, T T : Temperature ρ : Material density c : Specific heat g : Heat generation rate t : Time k : Thermal conductivity v : Web speed ) 4S Scientific 17

18 4S Scientific 18 Stationary thermal field in moving web 0 ),,, ( ˆ = + + Δ T z y x g x T v T α 0 ),, ( = T y x G x T v y T x T α α And after averaging in thickness direction (z axis) α cρ k / = Here

19 Realization of Alternating Direction computational method 2 T 2 T T T α x 2 + α y 2 + v x + G( x, y, T) = t 4S Scientific 19

20 Model verification The software was validated and upgraded using experimental data from Acktar Ltd. roll coaters The values predicted by the model were found to be very close to actual measurements done on a 500 mm wide aluminium foils. The coating processes were carried out in a double side roll coater on drum and in free-span mode. 4S Scientific 20

21 Closing Remarks The software is result of 10 years development. During the last few years, in parallel to the development, the software was validated and upgraded using Acktars one sided and double sided Roll Coaters. Acktar Ltd. is now an official distributor of the software. Proflex 2007 is a first public presentation of this software version. 4S Scientific 21

22 Thank you for your attention! 4S Scientific 22