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Vacuum Deposition onto Webs, Films, and Foils
- 1st Edition - December 20, 2006
- Author: Charles Bishop
- Language: English
- eBook ISBN:9 7 8 - 0 - 0 8 - 0 9 4 7 3 1 - 0
- eBook ISBN:9 7 8 - 0 - 8 1 5 5 - 1 9 4 7 - 8
This new book from William Andrew Publishing is the only practical reference available for anyone employing the roll-to-roll deposition process. Vacuum Deposition onto Webs, Films… Read more
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Request a sales quoteThis new book from William Andrew Publishing is the only practical reference available for anyone employing the roll-to-roll deposition process. Vacuum Deposition onto Webs, Films and Foils is an expansive journey of the process; benefiting manufacturing efficiency, unit cost reduction, and financial results. It is a sweeping approach to the total design of the vacuum deposition process written by a successful and world renowned consultant with three decades of experience.
Roll-to-roll deposition processing is a high growth industry and this reference covers a wide variety of important industrial products that use vacuum deposited coatings, including: optical storage devices, metallized packaging films, energy conservation windows, electronic information displays, and magnetic electronic article surveillance (EAS) tags among many others. This book is a must-have for roll-to-roll machine operators, process engineers, and research and development engineers throughout industry.
The book provides a broad appreciation of roll-to-roll vacuum deposition systems and processes. It will encourage a more comprehensive look from material supply through to the downstream processes that the product will encounter. It is a truly unique reference written to guide operators and engineers as an onsite consultant would.
Roll-to-roll deposition processing is a high growth industry and this reference covers a wide variety of important industrial products that use vacuum deposited coatings, including: optical storage devices, metallized packaging films, energy conservation windows, electronic information displays, and magnetic electronic article surveillance (EAS) tags among many others. This book is a must-have for roll-to-roll machine operators, process engineers, and research and development engineers throughout industry.
The book provides a broad appreciation of roll-to-roll vacuum deposition systems and processes. It will encourage a more comprehensive look from material supply through to the downstream processes that the product will encounter. It is a truly unique reference written to guide operators and engineers as an onsite consultant would.
This reference covers a wide variety of important industrial products that use vacuum deposited coatings, including: optical storage devices, metallized packaging films, energy conservation windows, electronic information displays, and magnetic electronic article surveillance (EAS) tags among many others. This book is a must-have for roll-to-roll machine operators, process engineers, and research and development engineers throughout industry.
Section I: Vacuum Basics
What is a vacuum?
What is a gas?
Pressure
Partial Pressure
Vapour pressure
Saturated Vapour Pressure
Why do we need a vacuum?
Mean Free Path
2. Products using vacuum deposited coatings
Metallized packaging films
Capacitor films
Optical data storage (ODS) tapes
Holographic coatings
Flake Pigments
Transparent barrier coatings
Transparent conducting coatings (TCOs)
Energy conservation windows
Solar cells
Solar absorbers
Flexible circuits
Optical variable devices (OVDs)
Magnetic electronic article surveillance (EAS) tags
Pyrotechnics
Thin film batteries
3. Pressure Measurement
Bourdon gauge
Pirani & Thermocouple gauges
Capacitance Manometer
Penning or cold cathode ionisation gauge
Ion or hot cathode ionisation gauge
4. Pumping
Rotary or Roughing pumps
Rootes pumps or blowers
Diffusion pumps
Turbomolecular pumps
Getter or sputter ion pump
Cryopumps
Pumping strategy
System pumping
5. Process Diagnostics & Coating Characteristics
Reflectance (R), Transmittance (T) & Absorbtance (A) measurements
Optical Density R,T, & A measurements
Conductivity / resistivity
On-line resistance monitoring
Transparent conducting coatings
Residual Gas Analysers (RGA)
Plasma Emission Monitors (PEM)
Thickness
Barrier
Neural Network control systems
Chemometrics
Surface energy measurements
Emissivity
6. Leaks, water vapour and leak testing
Real leaks
Imaginary leaks
Outgassing & Water Vapour
Leak Detection
7. Mass spectrometers, Helium leak detectors & residual gas analysers
Section II: Substrates, surface modification and nucleation
8. Substrates - surface quality, cleaning - adhesion & adhesion testing
Substrates
Polymer Surface quality
Substrate Cleaning
Surface Etching
Metal web & surface quality
Metal surface contamination
Paper
Foams, non-wovens, textiles
The 'Sellotape' test
Adhesion tests
Cores
Packaging
9. Surface treatment of webs & foils
Cleaning & Sealing
Cleaning System design considerations
Polymer coating basic information
10. Nucleation, coalescence & film growth.
Thin film û Thick film
Nucleation
Coalescence
Network & percolation threshold
Holes
Film growth
Energy
Electrical & Optical performance
Crystal Structure
Deposition rules of thumb
Section III. Process
11. The D.C. Glow Discharge or Plasma
The Townsend Discharge
The Breakdown Voltage
The Transition region
The Normal Glow Discharge
The Abnormal Glow Discharge
The Arc
Triodes and Magnetically enhanced plasmas
12. Electron beam (e-beam) evaporation
Filaments and electron emission
E-beam control
Power supply
Crucibles and feed systems
System design
13. Thermal evaporation
Boats
Wire feeding
Wire
Spitting & Pinholes
Thin film measurement
Power supplies & control
Coating uniformity
14. Radiant heated and Induction heated sources
Radiant heated sources
Radiation shields
Induction heated sources
15. Chemical Vapour Deposition / Polymerisation onto webs.
Substrate temperature
Power Pressure
Substrate bias
Fluorinated plasma polymerisation
Carbon - Fluorine plasmas
CVD of Barrier coatings
16. Planar Magnetron Sputtering source design and operation.
D.C. planar magnetron sputtering source
Balanced and Un-balanced magnetron sputtering
Anodes
Radio Frequency (RF) sputtering
Arcing and control of arcs
Water-cooling
End effects
Troubleshooting magnetron sputtering sources
17. Planar magnetron design options.
Single or Dual magnetron sputtering source
Anode included or not?
Balanced or unbalanced magnetic fields
Fixed or variable magnetic performance
Internal or external fitting
Direct or indirect cooling
Single or multiple materials
Linked or isolated cathodes
Cost implications
Coating uniformity
Magnets
18. Reactive deposition û set-up & control
Target preconditioning
Control options
Hysteresis loop
Monitors
Time constants
Pumping
Control of arcs
RF sputtering
Section IV: System issues
19. Machine specification & build issues
Risk Analysis - process
Mistake-proofing or Fool-proofing
Project Management
Safety
Costs
Machine specification
Maintenance & spares
20. Heat load on the webs/foils
Introduction
Potential winding problems
Characteristic winding problems associated with too much heat
Heating webs
21. Process variables
Drum surface roughness
Polymer surface roughness
Material properties
Deposition rate and winding speed
Water content of polymer
Drum temperature
Single or double side coating
Source type
Heat load calculations
Heat transfer coefficient
22. Mechanical design
Pumping
Non-Uniform pumping
Shields
23. Winding webs in vacuum
System design
Tension measurement û load cells
Alignment & roll spacing
Materials
Related items & materials
Substrates û variable width & tension
Key points on winding
Safety
24. Metallizer machine building trends
Metallizers
Speciality machines
25. System design
System choices
Batch vs air-to-air processing
26. Hazards
Risk Assessment
Mechanical
Electrical
Thermal
Chemical
Material Interactions
Hazardous gases
Cold traps & Cryopumps
Cleaning hazards
Ergonomic & Miscellaneous.
27. Troubleshooting
Troubleshooting vacuum
Troubleshooting process
Troubleshooting winding problems
Troubleshooting adhesion
Troubleshooting - common problems & diagnostic tools
Thermal evaporation by resistance heated boats
What is a vacuum?
What is a gas?
Pressure
Partial Pressure
Vapour pressure
Saturated Vapour Pressure
Why do we need a vacuum?
Mean Free Path
2. Products using vacuum deposited coatings
Metallized packaging films
Capacitor films
Optical data storage (ODS) tapes
Holographic coatings
Flake Pigments
Transparent barrier coatings
Transparent conducting coatings (TCOs)
Energy conservation windows
Solar cells
Solar absorbers
Flexible circuits
Optical variable devices (OVDs)
Magnetic electronic article surveillance (EAS) tags
Pyrotechnics
Thin film batteries
3. Pressure Measurement
Bourdon gauge
Pirani & Thermocouple gauges
Capacitance Manometer
Penning or cold cathode ionisation gauge
Ion or hot cathode ionisation gauge
4. Pumping
Rotary or Roughing pumps
Rootes pumps or blowers
Diffusion pumps
Turbomolecular pumps
Getter or sputter ion pump
Cryopumps
Pumping strategy
System pumping
5. Process Diagnostics & Coating Characteristics
Reflectance (R), Transmittance (T) & Absorbtance (A) measurements
Optical Density R,T, & A measurements
Conductivity / resistivity
On-line resistance monitoring
Transparent conducting coatings
Residual Gas Analysers (RGA)
Plasma Emission Monitors (PEM)
Thickness
Barrier
Neural Network control systems
Chemometrics
Surface energy measurements
Emissivity
6. Leaks, water vapour and leak testing
Real leaks
Imaginary leaks
Outgassing & Water Vapour
Leak Detection
7. Mass spectrometers, Helium leak detectors & residual gas analysers
Section II: Substrates, surface modification and nucleation
8. Substrates - surface quality, cleaning - adhesion & adhesion testing
Substrates
Polymer Surface quality
Substrate Cleaning
Surface Etching
Metal web & surface quality
Metal surface contamination
Paper
Foams, non-wovens, textiles
The 'Sellotape' test
Adhesion tests
Cores
Packaging
9. Surface treatment of webs & foils
Cleaning & Sealing
Cleaning System design considerations
Polymer coating basic information
10. Nucleation, coalescence & film growth.
Thin film û Thick film
Nucleation
Coalescence
Network & percolation threshold
Holes
Film growth
Energy
Electrical & Optical performance
Crystal Structure
Deposition rules of thumb
Section III. Process
11. The D.C. Glow Discharge or Plasma
The Townsend Discharge
The Breakdown Voltage
The Transition region
The Normal Glow Discharge
The Abnormal Glow Discharge
The Arc
Triodes and Magnetically enhanced plasmas
12. Electron beam (e-beam) evaporation
Filaments and electron emission
E-beam control
Power supply
Crucibles and feed systems
System design
13. Thermal evaporation
Boats
Wire feeding
Wire
Spitting & Pinholes
Thin film measurement
Power supplies & control
Coating uniformity
14. Radiant heated and Induction heated sources
Radiant heated sources
Radiation shields
Induction heated sources
15. Chemical Vapour Deposition / Polymerisation onto webs.
Substrate temperature
Power Pressure
Substrate bias
Fluorinated plasma polymerisation
Carbon - Fluorine plasmas
CVD of Barrier coatings
16. Planar Magnetron Sputtering source design and operation.
D.C. planar magnetron sputtering source
Balanced and Un-balanced magnetron sputtering
Anodes
Radio Frequency (RF) sputtering
Arcing and control of arcs
Water-cooling
End effects
Troubleshooting magnetron sputtering sources
17. Planar magnetron design options.
Single or Dual magnetron sputtering source
Anode included or not?
Balanced or unbalanced magnetic fields
Fixed or variable magnetic performance
Internal or external fitting
Direct or indirect cooling
Single or multiple materials
Linked or isolated cathodes
Cost implications
Coating uniformity
Magnets
18. Reactive deposition û set-up & control
Target preconditioning
Control options
Hysteresis loop
Monitors
Time constants
Pumping
Control of arcs
RF sputtering
Section IV: System issues
19. Machine specification & build issues
Risk Analysis - process
Mistake-proofing or Fool-proofing
Project Management
Safety
Costs
Machine specification
Maintenance & spares
20. Heat load on the webs/foils
Introduction
Potential winding problems
Characteristic winding problems associated with too much heat
Heating webs
21. Process variables
Drum surface roughness
Polymer surface roughness
Material properties
Deposition rate and winding speed
Water content of polymer
Drum temperature
Single or double side coating
Source type
Heat load calculations
Heat transfer coefficient
22. Mechanical design
Pumping
Non-Uniform pumping
Shields
23. Winding webs in vacuum
System design
Tension measurement û load cells
Alignment & roll spacing
Materials
Related items & materials
Substrates û variable width & tension
Key points on winding
Safety
24. Metallizer machine building trends
Metallizers
Speciality machines
25. System design
System choices
Batch vs air-to-air processing
26. Hazards
Risk Assessment
Mechanical
Electrical
Thermal
Chemical
Material Interactions
Hazardous gases
Cold traps & Cryopumps
Cleaning hazards
Ergonomic & Miscellaneous.
27. Troubleshooting
Troubleshooting vacuum
Troubleshooting process
Troubleshooting winding problems
Troubleshooting adhesion
Troubleshooting - common problems & diagnostic tools
Thermal evaporation by resistance heated boats
- No. of pages: 495
- Language: English
- Edition: 1
- Published: December 20, 2006
- Imprint: William Andrew
- eBook ISBN: 9780080947310
- eBook ISBN: 9780815519478
CB
Charles Bishop
Charles started his working life as an apprentice in mechanical engineering finishing as a toolmaker. He has a degree in Materials Engineering and Masters and Doctorate Degrees by research in vacuum deposition onto polymer webs. He now has accumulated over 35 years experience in vacuum deposition onto webs with the last 15 spent running his own consultancy business. He has published over 85 technical articles and papers, has 5 patents & has run training courses in Asia, Europe and USA. He has written two books ‘A guide to roll-to-roll vacuum deposition of barrier coatings’ and ‘Vacuum Deposition onto Webs, Films & Foils’, now into the 2nd edition and contributed chapters on transparent conducting coatings and packaging coatings in two other books. Charles is a Blog editor on behalf of AIMCAL and has a regular column in Converting Quarterly.
Affiliations and expertise
CAB Consulting, Ltd.Read Vacuum Deposition onto Webs, Films, and Foils on ScienceDirect