Precision Multilayer Coating and Manufacturing Partnerships

Precision, multi-layer solution coating processes are ideally suited for the manufacture of high-performance cast films, including polyurethane (PU) films. Solution casting a polymer dissolved in a solvent onto a temporary substrate has many advantages over the traditional extrusion of molten polymer through a die, including more uniform thickness distribution, higher dimensional stability and optical purity. Also, multi-layer coating processes enable the addition of functional coatings during the film casting process, eliminating the cost of secondary coating steps.

Energy storage devices include everything from fuel cells and lithium ion batteries to grid storage and other novel technologies. Their design and construction is increasingly complex, as markets demand smaller, more powerful, lower-cost, and longer-life devices for different applications. Carestream Contract Manufacturing’s precision coating, rapid prototyping and process development expertise, along with its high-speed, wide-web assets and technologies, provide exceptional qualifications for this emerging market.

Proper management of solution delivery systems and procedures ensures optimum product quality and cost control. Throughout the process, clear, operationally sound procedures help maintain technical efficiency. Part One of this article focused on system design. Now we’re ready to discuss how system performance can be optimized to improve product quality and yield.

Precision coating encompasses sophisticated, highly controlled functions, including distribution of liquid across a conveying web and control of coating thickness in the down-web direction. Uniform coatings require precise fluid metering, precision coating heads, and tight conveyance speed and tension controls. Thus, an operation’s capabilities are partially defined by the quality and accuracy of solution delivery systems—how the fluid gets to the coating method.

Protective films for displays, touch screens and other consumer electronic devices help prevent damage from everyday mishaps – ultimately saving consumers and business owners from costly repair and replacement costs. Hardcoated films improve performance and protect against abrasions, scratches and chemicals by imparting a durable, scratch-resistant surface that looks and wears like glass when adhered to any product surface. Carestream’s hardcoated film construction features a proprietary hardcoat formulation and delivers reduced iridescence.

Polymer solution casting is a technique that can replace film extrusion to deliver high-quality films with superior optical, mechanical and physical film properties. In polymer solution casting, polymer is dissolved or dispersed in solution, coated onto a carrier substrate, and then the water or solvent is removed by drying to create a solid layer on the carrier. The resulting cast layer can be stripped from the carrier substrate to produce a standalone film.