High Speed SolventFree Process for

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SMART COATINGS, 2006
Surface Functionalization of Materials

• High Speed Solvent-Free Process for
• Wide Web Polymer Coatings
• By
• Michael G. Mikhael
• Sigma Technologies International Inc.
• 10960 N. Stallard Pl.
• Tucson, AZ 85737
• www.sigma-technologies.com

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SIGMAS PRODUCT MIX

• Plasma Treatment Equipment
• Vacuum Plasma
• Atmospheric Plasma
• Coating Equipment
• Flash Evaporation
• Polymer Coating
• Radiation Curing
• Physical Vapor Deposition
• Sputtering
• Technology Licensing
• Specialty Coated Products

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UNIQUE SURFACE FUNCTIONALIZATION TECHNOLOGIES
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VACUUM POLYMER COATING
Polymer Coating
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ADVANTAGES of POLYMER COATING in VACUUM

• Roll-to-Roll Wide Web Coating (up to 4 meters)
• The Process is Compatible with Inline Metal
  Evaporation and Sputtering
• Nanolayer Solvent/Water Free High Speed
  Deposition (up to 500 meter/min)
• Encapsulation of Individual Fibers without
  Blocking Porous Surfaces
• Smoothing and Leveling Effect
• Contained Process with no Environmental Impact
• Applying different Functionality on Both Sides of
  the Web (hydrophobic/hydrophilic)
• Inline Patterning for Polymer and Metal Coatings

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FLASH EVAPORATION VACUUM POLYMER DEPOSITION WITH
RADIATION CURING
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SCHEMATIC OF COATING SYSTEMS
VACUUM POLYMER COATING CHAMBER
VACUUM METALLIZING AND POLYMER COATING CHAMBER
Plasma Treater
Plasma Treater
Monomer Evaporator
Electron Beam Curtain
Monomer Evaporator
Electron Beam Curtain
Monomer Evaporator
Metallization Station
Electron Beam Curtain
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POLYMER VACUUM COATING

• Monomer Evaporation
• Why Flash Evaporation?
• Limitations
• Monomer Mw and vapor pressure
• Radiation curing chemistry (free radical and
  cationic)
• Critical Factors
• Size of the evaporator
• Equilibrium Between Evaporation and Condensation
• Monomer atomization
• Monomer feed rate

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ADVANTAGES OF THE FLASH EVAPORATION PROCESS

• Overcomes the Problem of Solubility of Different
  Materials in Acrylate Binders
• No solubility limitation in the dye/binder
  formulation
• Perfect Molecular Level Dispersion in Vapor Phase
• Thin Liquid Deposited Layer Remains Homogeneous
• Cross Linking within Milliseconds from Deposition
  Freezes the Structure and Prevents Phase
  Separation
• More than 95 Chemical Utilization.

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OTHER FACTORS

• Simple 100 Solids Chemistry
• Reduce materials inventory
• Greater flexibility
• Zero Negative Environmental Effects
• No reclamation requirements, water treatment,
• Reduced Plant Space Requirements
• 100m2 vs 350m2
• Better Performance

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CHARACTERISTICS OF ACRYLATE COATINGS

• Clear and Transparent Films
• Good Abrasion Resistance
• Coating Thickness ranges from 20nm to Several
  Microns
• High Temperature Polymers gt250oC
• Unique Surface Leveling Properties
• Surface Energies from 20 dyne/cm2 to 75 dyne/cm2
• Low Raw Material Cost

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VACUUM COATING AND CURING EQUIPMENTS
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48 VACUUM COATING CHAMBER
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EQUIPMENTS Sigma Has Sold Several Turn Key
Coating Equipment for Different Applications
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APPLICATIONS Pigmented colored coating
Examples of High Chromophore Content in a Uniform
Sub-Micron Coatings
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APPLICATIONS Electroluminescence

• Examples of Small Molecules Organic Light
  Emitting Diodes (OLED)

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APPLICATIONS Functional Coatings for Porous
Materials, Paper, Fabrics and Non-woven
Substrates
Converting Non Woven PP Fabric to Teflon-Like
Oil/Water Repelling Media
Sigma Coated Oil and Water Repellant
Oil Wetting and Water Repellant (control)
Oil Water
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APPLICATIONS Functional Coatings for Porous
Materials, Paper, Fabrics and Non-woven
Substrates

• Sigmas Coated
• Oil and Water
  Wetting
• Oil Wetting
• Water Repellant
• (control)
• Oil Water

Converting Non Woven PP Fabric to Paper-Like
Water Transmitting Media
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APPLICATIONS Functional Coatings for Porous
Materials, Paper, Fabrics and Non-woven
Substrates
Converting Rayon Fabric to Teflon-Like Oil/Water
Repelling Media

• Oil and Water Wetting
• (control)
• Sigmas Coated
• Oil and Water Repellant
• Oil Water

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APPLICATIONS Functional Coatings for Porous
Materials, Paper, Fabrics and Non-woven
Substrates
Non Coated Fabric Coated Fabric
Non-Woven Polypropylene Surface Functionalization
with no Effect on Breathability
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APPLICATIONS Leveling coating

• Smooth leveling layer
• Binding to ITO anode
• Thermal / chemical resistance

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APPLICATIONS FOR FLASH EVAPORATION VACUUM COATINGS

• Moisture and Vapor barrier coatings
• Pigmented colored and color shift coatings
• Functional coatings for paper, fabrics and
  non-woven materials
• Selective coating on each side of the web
• Leveling coating
• Chemical resistance
• Chemical sensing
• Metal chelating
• Flame resistance coatings
• Release coatings

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(Continued) APPLICATIONS FOR FLASH EVAPORATION
VACUUM COATINGS

• Antibacterial coatings (Cl, Ag and QAC)
• Antireflection (low/high reflective index
  coatings)
• Polyelectrolyte thin film
• Low emissivity heat reflective coatings
• IR/RF coatings for signature control
• Metal Flakes (high aspect ratio)
• Controlled surface
• Hydrophobic-oleophilic
• Hydrophobic-oleophobic
• Hydrophilic-oleophilic
• Alcohol resistant

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THANK YOUAny Question?--------------------------
---------------------------------------CONTACT
INFORMATIONMichael G. MikhaelSigma Technologies
Intl.10960 N. Stallard Pl., Tucson, AZ
85737520-575-8013mikh_at_sigmalabs.comwww.sigmalab
s.com
Plasma and Coating Technologies