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ISCST is planning to offer two short courses at the 2008 ISCST Symposium in Marina del Rey, Califonia. The short courses will be held on September 6 & 7, 2008 and the Symposium presentations will be September 7-10, 2008.
Registration Form
Science & Technology of Coating and Drying Processes
(2-Day)
September 6-7, 2008
Registration Fee: $1,095.00
Minimum registration to hold course: 15
Purpose
This course will cover scientific, technological and practical aspects of continuously coating and drying flexible substrates. The focus will be on the underlying physical concepts that govern coating and drying processes, starting with fluid conditioning and delivery, including liquid distribution and coating, and ending with solidifying the coated film.
Intended Audience
The course is designed for coating engineers, technologists, and machine operators working with precision coating processes.
Format
Each subject will be lectured by an experienced and renowned expert by way of PowerPoint presentations.
Materials
Each course attendee will receive a folder containing copies of the PowerPoint slides, as well as a list of the course participants.
Program
Introduction (Peter Schweizer))
Overview of the coating industry, major components of industrial coating machines, concepts for pilot coating machines, difference between a coating machine and a coating process, overview of different coating methods, criteria for selecting the best possible coating method.
Fluid mechanics of coating flows (Steven Weinstein)
Basic principles governing fluid flows including conservation of mass and force balance on fluids (viscous, pressure, gravity, inertia), force implication in simplified coating process, physics of fluid-fluid interfaces, molecular origin of surface tension, force balance at interface (interfacial curvatures and flow, surfactant and temperature-induced flows), contact angles and air entrainment.
Physical fluid properties and measurement methods (Kenneth Ruschak)
Introduction (Coating flows, relevant properties and phenomena of liquids, complications of coating practice, the purposes of measurements), bulk and component densities (relevance, measurements), surface tension and energy (interfacial phenomena, relevance, static surface tension, dynamic surface tensions and their differences, contact angle and spreading, diagnostic coatings), rheology (rheological phenomena, relevance, generalized Newtonian constitutive equations, viscometers and rheometers, index measurements), other useful measurements.
Fluid conditioning and delivery (Peter Schweizer)
Major processes and components of delivery systems, including pumps, flow meters, filters, degassing and bubble removal, temperature control, on-line injection and in-line mixing, contamination and cleaning, criteria for configuring delivery systems.
Die Design (Kenneth Ruschak)
Introduction (functions, general requirements), geometric elements (slots, cavities, inlets, external flow surfaces, lips), general principles and considerations (flow resistance partitioning, flow patterns, mechanical distortions, displacing air, displacing one liquid with another, flow on external surfaces), internal design space (dimensionless groups of parameters, general options and tradeoffs), external design space (slot exits, flow surface inclination and length, die height), mechanical tolerances and distortions.
Self-metered coating methods (Marcio Carvalho)
Overview of self metering coating methods, introduction to roll coating methods, forward roll coating, reverse roll coating, roll coating with deformable rolls, roll coating systems.
Pre-metered coating methods (Peter Schweizer)
Overview of premetered coating methods, attractiveness of simultaneous multilayer coating applications, introduction to slot, slide and curtain coating, explanations of operating boundaries.
Drying and curing (Brent Bell)
Brief review of the drying industry, drying of coated webs, drying process basics, heat and mass transfer concepts, essential psychrometrics, key process parameters, key product parameters, drying regimes, product examples (aqueous, solvent), UV curing, drying equipment/dryer types, energy input, air handling schemes, air impingement and conveyance methods, process sensors, auxiliary equipment, drying model as a tool (drying curves), description of common drying tasks, optimum dryer setup, evaluation of the effects of product changes on process operation, evaluation of dryer limitations, reduction of dryer energy usage, dryer design, common drying defects and problems (orange peel, convection cells, Benard cells, mottle, blush, haze, patterns, drying stresses (curl, cracking, delamination), skinning).
Faculty
Dr. Brent C. Bell
Brent received his PhD in Mechanical Engineering from the University of Kansas in 1993 and then spent one year in post-doctoral study in the Department of Chemical Engineering at the University of Minnesota in 1994. During his graduate and post-graduate studies, he developed computer models for both coating and drying processes.
Brent's first industrial position was with Eastman Kodak Co. where he worked for 21 years in R&D of coatings and coating and drying processes. He was responsible for the development of the company's drying modeling tools and for the design and optimization of both aqueous and solvent drying processes. Brent won Kodak's highest research award, the CEK Mees award, in 2001 and also the company's Software Excellence award in 2004.
Currently, Brent works for Isoflux Biomed in R&D of coatings for biomedical devices. In addition, he is also an Adjunct Professor of Chemical Engineering at the University of Rochester.
Professor Marcio Carvalho
Marcio has been active in coating research and development for more than 15 years. He received his PhD in Chemical Engineering from the University of Minnesota in 1995, with a thesis on the basic mechanisms, experiments, theory and computer aided analysis of roll coating processes that make use of deformable rolls. He worked as Senior Process Development Engineer at 3M Company and Imation Corporation in the areas of pre-metered coating, roll coating and drying technologies. Now Marcio is an Associate Professor in the Department of Mechanical Engineering at Pontificia Universidade Catolica do Rio de Janeiro, in Brazil. Marcio is a member of the Graduate Faculty in the Department of Chemical Engineering & Materials Science at the University of Minnesota. His research is focused on several aspects of coating process, non-Newtonian fluid mechanics and micro scale flow of emulsions.
Marcio received the Young Investigator Award from the International Society for Coating Science and Technology (ISCST) in 2004. He consults in coating and drying processes for different companies in Brazil, USA, Japan and Europe.
Dr. Kenneth J. Ruschak
Ken has a B.S. degree from Carnegie-Mellon University and a Ph.D. degree from the University of Minnesota in Chemical Engineering. His thesis, Coating Flows, was under the direction Prof. L. E. Scriven.
In a 33 year career at Eastman Kodak Co., Ken worked on the research, development, implementation, application, and documentation of coating technology. Applications included photographic film and paper manufacturing, ink jet paper manufacturing, and dye sublimation film manufacturing. His interests include mathematical modeling in Newtonian and non-Newtonian fluid mechanics and capillary hydrodynamics, the rheology of polymer solutions and pigment dispersions, coating die and coating station development and design, and coating practice in simultaneous multilayer curtain and slide bead coating, slot die coating, gravure coating, and rod and blade coating. He has 29 Eastman Kodak Co. Technical Reports, 33 patents, and 30 external publications. At Kodak he received the Distinguished Inventors' Award, the Eastman Innovation Award, and the C. E. K. Mees Award. He also received the John A. Tallmadge Award for Contributions to Coating Technology from the AIChE.
Currently he is a part-time research professor in the Kate Gleason College of Engineering at the Rochester Institute of Technology where he is helping to start a program in liquid films and promoting industrial collaborations.
Dr. Peter M. Schweizer
Peter received his PhD in Mechanical Engineering from the Swiss Federal Institute of Technology in 1979, and he did post-doctoral research in coating flows at the University of Minnesota with Prof. Scriven in 1979 - 1980.
From 1981 - 1986, Peter worked in the Coating Flow Research Group at Kodak in Rochester, New York.
From 1987 - 1996, he worked at ILFORD in Fribourg, Switzerland, where he assumed responsibilities for Process Technology and Engineering.
From 1997 - 2000, Peter was Managing Director of TSE Troller Schweizer Engineering in Switzerland, one of the leading manufacturers of coating dies.
Since 2001, Peter works for Polytype Converting in Fribourg, Switzerland, a supplier of coating and drying processes and a manufacturer of coating machines, where he is responsible for Process Development.
Peter is co-editor of the book entitled Liquid Film Coating, which appeared in 1997. In 2006, he received the John A. Tallmadge Award for Contributions to Coating Technology from the International Society for Coating Science and Technology (ISCST).
Prof. Steven Weinstein
Steve received his PhD in Chemical Engineering from the University of Pennsylvania in 1988.
Steve worked for Eastman Kodak Company for 18 years after receiving his PhD. His areas of expertise are interfacial fluid mechanics, transport phenomena, and applied mathematics. He has published over 25 refereed articles in the field of coating, and he has 7 patents in these areas. Steve has won the CEK Mees award for excellence in research and technical writing (1992; honorable mention 1998), the highest research award bestowed by Eastman Kodak Company.
While at Kodak, Steve was also an Adjunct Professor of Chemical Engineering at the University of Rochester, and he was an Adjunct Professor of Mechanical Engineering at the Rochester Institute of Technology. Moreover, he is also an Adjunct Professor of Chemical and Biomolecular Engineering at Cornell University, and has co-advised students there for their PhD.
In 2000, Steve was the recipient of the Young Investigator Award from the International Society of Coating Science and Technology. He has served on the board of directors of this society since 2004.
In 2007, Steve joined the faculty in the Department of Mechanical Engineering at Rochester Institute of Technology. His teaching activities include core graduate mathematics for engineers, graduate convective phenomena, and undergraduate fluid dynamics. In addition, he has developed an undergraduate minor in Chemical Engineering Systems Analysis and is responsible for teaching its core courses including material balances in reactive systems, reaction engineering, and mass transfer operations.
Registration Form
The Role of Modeling & Visualization in the Coating Process
(1 day)
September 7, 2008
Registration Fee: $795.00
Minimum registration to hold course: 6
The Coating industry today often requires production improvements and quick development of new products. Thinner and thinner liquid layers are now more frequently applied to substrates as multilayer coatings at tight thickness tolerances and at higher and higher line speeds, and less production waste. Complete understanding of the different processes help coating professionals to meet the product development and production challenges they face everyday. It is important to analyze the physical mechanisms that determine the success or failure of a process. Flow visualization and computer aided modeling are priceless tools available to coating professionals today. Methods, techniques and modern equipment developed at the University of Minnesota (Minneapolis), Pontificia Universidade Catolica (Rio de Janeiro) and other places, used in successful visualization and modeling of roll, slot, slide, curtain, and other types of coating techniques are discussed in this course. The ways how both of these approaches (experimental and theoretical) interact and complement each other leads to better process understanding is also presented along with several examples.
Program
- Overview of fundamental analysis of coating processes.
- Special coating equipment designed for visualization: transparent rolls, glass shoes, coating dies, and others.
- Proper selection of lenses, cameras, recording equipment and lighting.
- Visualization techniques most useful in coating and solidification processes.
- Numerical Methods for Modeling Coating Processes: Viscocapillary and Navier-Stokes models of free surface flows.
- Experiments and Theory: Examples of combined experimental and theoretical analysis in slot, slide, curtain, tensioned web, roll, gravure and other coating techniques.
Faculty
Professor Marcio Carvalho
Marcio has been active in coating research and development for more than 15 years. He received his PhD in Chemical Engineering from the University of Minnesota in 1995, with a thesis on the basic mechanisms, experiments, theory and computer aided analysis of roll coating processes that make use of deformable rolls. He worked as Senior Process Development Engineer at 3M Company and Imation Corporation in the areas of pre-metered coating, roll coating and drying technologies. Now Marcio is an Associate Professor in the Department of Mechanical Engineering at Pontificia Universidade Catolica do Rio de Janeiro, in Brazil. Marcio is a member of the Graduate Faculty in the Department of Chemical Engineering & Materials Science at the University of Minnesota. His research is focused on several aspects of coating process, non-Newtonian fluid mechanics and micro scale flow of emulsions.
Marcio received the Young Investigator Award from the International Society for Coating Science and Technology (ISCST) in 2004. He consults in coating and drying processes for different companies in Brazil, USA, Japan and Europe.
Wieslaw J. Suszynski
Wieslaw is the Research Engineer in charge of the Coating Process Fundamentals Laboratory at the University of Minnesota. He is responsible for the design and operation of the experimental coating equipment and associated instrumentation as well as scientific visualization, photography, standard and high-speed video imaging. Wieslaw has participated in the development of coating and drying visualization technology in the Coating Process Fundamentals Program for more than 17 years since its early stages. Wieslaw has done work within the University and in collaboration with several Interfacial and Materials Research Center Member Companies. He graduated from the Cracow University of Technology, Poland, where he received his MSChE degree
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