{"product_id":"coating-and-drying-defects-troubleshooting-operating-problems-2nd-edition-society-of-plastics-engineers-monographs-9780471713685","title":"Coating and Drying Defects Troubleshooting","description":"\u003cb\u003eBook Synopsis\u003c\/b\u003e\u003cbr\u003eA practical guide for ensuring a defect-free coating and drying process For professionals in the coating and drying industry, the world is a demanding place. New, technically complex products such as fuel cell membranes, thin film batteries, solar cells, and RFID chips require coatings of extreme precision.\u003cbr\u003e\u003cbr\u003e\u003cb\u003eTrade Review\u003c\/b\u003e\u003cbr\u003e\"…this text belong center stage in all college-level libraries--a one-of-a-kind resource that speaks to its subject in eloquent and comprehensive terms.\" (\u003ci\u003eElectric Review\u003c\/i\u003e, February\/March 2007)\u003cbr\u003e\u003cbr\u003e\u003cb\u003eTable of Contents\u003c\/b\u003e\u003cbr\u003e\u003cp\u003ePreface xv\u003c\/p\u003e \u003cp\u003ePreface to the First Edition xvii\u003c\/p\u003e \u003cp\u003eAbout the Authors xxi\u003c\/p\u003e \u003cp\u003e\u003cb\u003e1 Introduction 1\u003c\/b\u003e\u003c\/p\u003e \u003cp\u003e\u003cb\u003e2 Troubleshooting or Problem-Solving Procedure 5\u003c\/b\u003e\u003c\/p\u003e \u003cp\u003eBasic Troubleshooting Principles 6\u003c\/p\u003e \u003cp\u003eDetect the Defect 8\u003c\/p\u003e \u003cp\u003eDefine the Defect or Problem 9\u003c\/p\u003e \u003cp\u003eName the Defect 11\u003c\/p\u003e \u003cp\u003eProblem Statement 15\u003c\/p\u003e \u003cp\u003eCollect and Analyze Additional Data 16\u003c\/p\u003e \u003cp\u003eProcess Information 16\u003c\/p\u003e \u003cp\u003eGeneral Process Information 17\u003c\/p\u003e \u003cp\u003eAnalytical Data 19\u003c\/p\u003e \u003cp\u003eStandard Operating Procedures 19\u003c\/p\u003e \u003cp\u003eAnalyze the Data and Identify Potential Causes of Problem 19\u003c\/p\u003e \u003cp\u003eEliminate the Problem 25\u003c\/p\u003e \u003cp\u003eDocument the Results 25\u003c\/p\u003e \u003cp\u003eUse Results to Prevent Reoccurrence 27\u003c\/p\u003e \u003cp\u003eReferences 27\u003c\/p\u003e \u003cp\u003e\u003cb\u003e3 Coater and Defect Analytical Tools 29\u003c\/b\u003e\u003c\/p\u003e \u003cp\u003eOverview of Analytical Tools 30\u003c\/p\u003e \u003cp\u003eAnalytical Methods to Characterize Defects 30\u003c\/p\u003e \u003cp\u003eDefect Test Procedures 31\u003c\/p\u003e \u003cp\u003eVideo Enhanced Microscopy 31\u003c\/p\u003e \u003cp\u003eSurface Characterization Techniques 33\u003c\/p\u003e \u003cp\u003eCoater Characterization Instruments 38\u003c\/p\u003e \u003cp\u003eData Loggers 42\u003c\/p\u003e \u003cp\u003eRheological Measurements 44\u003c\/p\u003e \u003cp\u003eSurface Properties 49\u003c\/p\u003e \u003cp\u003eOn-Line Characterization Systems 50\u003c\/p\u003e \u003cp\u003eOn-Line Inspection Systems 50\u003c\/p\u003e \u003cp\u003eOn-Line Coating Weight Measurement 52\u003c\/p\u003e \u003cp\u003eOn-Line Viscosity 54\u003c\/p\u003e \u003cp\u003eData Analysis Techniques 55\u003c\/p\u003e \u003cp\u003eKeeping Current 56\u003c\/p\u003e \u003cp\u003eReferences 61\u003c\/p\u003e \u003cp\u003e\u003cb\u003e4 Problems Associated with Feed Preparation 63\u003c\/b\u003e\u003c\/p\u003e \u003cp\u003eDirt and Other Particulates 63\u003c\/p\u003e \u003cp\u003eFiltration 64\u003c\/p\u003e \u003cp\u003eAgglomerates 66\u003c\/p\u003e \u003cp\u003eBubbles 68\u003c\/p\u003e \u003cp\u003ePoor Cross-Web Uniformity 69\u003c\/p\u003e \u003cp\u003eIn-Line Mixers 70\u003c\/p\u003e \u003cp\u003eTemperature Control 70\u003c\/p\u003e \u003cp\u003eFlow Control for Down-Web Uniformity 70\u003c\/p\u003e \u003cp\u003eFeeding the Coating Liquid 70\u003c\/p\u003e \u003cp\u003eFlow Control 72\u003c\/p\u003e \u003cp\u003eMagnetic Flow Meters 72\u003c\/p\u003e \u003cp\u003eUltrasonic Meters 73\u003c\/p\u003e \u003cp\u003eCoriolis Meters 73\u003c\/p\u003e \u003cp\u003eReferences 74\u003c\/p\u003e \u003cp\u003e\u003cb\u003e5 Problems Associated with Roll Coating and Related Processes 75\u003c\/b\u003e\u003c\/p\u003e \u003cp\u003eCoating Methods 75\u003c\/p\u003e \u003cp\u003eControl of Coating Weight 82\u003c\/p\u003e \u003cp\u003eRibbing 86\u003c\/p\u003e \u003cp\u003eRibbing in Forward Roll Coating 87\u003c\/p\u003e \u003cp\u003eRibbing and Cascade (or Herringbone or Seashore) in Reverse Roll Coating 89\u003c\/p\u003e \u003cp\u003eGravure Coating 92\u003c\/p\u003e \u003cp\u003eStreaks and Bands in Roll Coating 92\u003c\/p\u003e \u003cp\u003eChatter in Roll Coating 94\u003c\/p\u003e \u003cp\u003eSagging 94\u003c\/p\u003e \u003cp\u003eReferences 95\u003c\/p\u003e \u003cp\u003e\u003cb\u003e6 Problems in Slot Extrusion Slide and Curtain Coating 97\u003c\/b\u003e\u003c\/p\u003e \u003cp\u003eDescription of Coating Methods 97\u003c\/p\u003e \u003cp\u003eLimits of Coatability 107\u003c\/p\u003e \u003cp\u003eThe Window of Coatability 107\u003c\/p\u003e \u003cp\u003eSlide Coating 109\u003c\/p\u003e \u003cp\u003eVortices and Eddies 110\u003c\/p\u003e \u003cp\u003eSlot Coating 117\u003c\/p\u003e \u003cp\u003eExtrusion Coating 124\u003c\/p\u003e \u003cp\u003eCurtain Coating 126\u003c\/p\u003e \u003cp\u003eEffect of Surface Roughness on the Limits of Coatability 128\u003c\/p\u003e \u003cp\u003eInstabilities in Premetered Coating 131\u003c\/p\u003e \u003cp\u003eChatter 131\u003c\/p\u003e \u003cp\u003eRibbing 131\u003c\/p\u003e \u003cp\u003eNeck-in 133\u003c\/p\u003e \u003cp\u003eScalloped Edges 133\u003c\/p\u003e \u003cp\u003eEdge Beads and Heavy Edges 133\u003c\/p\u003e \u003cp\u003eWaves in Slide and in Curtain Coating 135\u003c\/p\u003e \u003cp\u003eStreaks and Bands in Premetered Coating 137\u003c\/p\u003e \u003cp\u003eReferences 141\u003c\/p\u003e \u003cp\u003e\u003cb\u003e7 Coating Problems Associated with Coating Die Design 143\u003c\/b\u003e\u003c\/p\u003e \u003cp\u003eCross-Web Uniformity 143\u003c\/p\u003e \u003cp\u003eTemperature Control 148\u003c\/p\u003e \u003cp\u003eCorrections to the Coating Die Internals 149\u003c\/p\u003e \u003cp\u003eDie Internal Pressures and Spreading 150\u003c\/p\u003e \u003cp\u003eExtrusion Dies 151\u003c\/p\u003e \u003cp\u003eWall Shear Stress Control and Residence Time Control 153\u003c\/p\u003e \u003cp\u003eReferences 155\u003c\/p\u003e \u003cp\u003e\u003cb\u003e8 Surface Tension Driven Defects 157\u003c\/b\u003e\u003c\/p\u003e \u003cp\u003eSurfactants 158\u003c\/p\u003e \u003cp\u003eSurface Tension Effects in Coating 159\u003c\/p\u003e \u003cp\u003eSurface Tension Driven Defects 162\u003c\/p\u003e \u003cp\u003eConvection or Bénard Cells 162\u003c\/p\u003e \u003cp\u003eCraters 163\u003c\/p\u003e \u003cp\u003eFat Edges or Picture Framing 164\u003c\/p\u003e \u003cp\u003eNonuniform Edges in Multilayer Coatings 165\u003c\/p\u003e \u003cp\u003eDewetting and Crawling 166\u003c\/p\u003e \u003cp\u003eAdhesive Failure and Delamination 167\u003c\/p\u003e \u003cp\u003eNonuniform Base Surface Energies 168\u003c\/p\u003e \u003cp\u003eReferences 168\u003c\/p\u003e \u003cp\u003e\u003cb\u003e9 Problems Associated with Static Electricity 169\u003c\/b\u003e\u003c\/p\u003e \u003cp\u003eFormation of Charges 171\u003c\/p\u003e \u003cp\u003eElectrostatic Fields 173\u003c\/p\u003e \u003cp\u003eSurface Resistivity 174\u003c\/p\u003e \u003cp\u003eMeasurement of Static Charges 177\u003c\/p\u003e \u003cp\u003eRemoval of Charges 180\u003c\/p\u003e \u003cp\u003eFree Charges 180\u003c\/p\u003e \u003cp\u003eBound Charges 182\u003c\/p\u003e \u003cp\u003eReferences 183\u003c\/p\u003e \u003cp\u003e\u003cb\u003e10 Problems Associated with Drying 185\u003c\/b\u003e\u003c\/p\u003e \u003cp\u003eDryer Control and Solvent Removal 189\u003c\/p\u003e \u003cp\u003eDrying Condition Case History 195\u003c\/p\u003e \u003cp\u003eDrying Defects 198\u003c\/p\u003e \u003cp\u003eAir Bar Rubs 199\u003c\/p\u003e \u003cp\u003eBlushing 199\u003c\/p\u003e \u003cp\u003eBubbles and Blisters 200\u003c\/p\u003e \u003cp\u003eCockle or Wrinkling 201\u003c\/p\u003e \u003cp\u003eCurl 201\u003c\/p\u003e \u003cp\u003eMud Cracking 204\u003c\/p\u003e \u003cp\u003eDelamination 204\u003c\/p\u003e \u003cp\u003eDryer Bands 205\u003c\/p\u003e \u003cp\u003eDryer Remelt 206\u003c\/p\u003e \u003cp\u003eDryer Contamination Spots 207\u003c\/p\u003e \u003cp\u003eDryer Condensation Spots 208\u003c\/p\u003e \u003cp\u003eHaze 208\u003c\/p\u003e \u003cp\u003eMottle 208\u003c\/p\u003e \u003cp\u003eOrange Peel and Crinkling 209\u003c\/p\u003e \u003cp\u003eOverspray 209\u003c\/p\u003e \u003cp\u003eReticulation 209\u003c\/p\u003e \u003cp\u003eSurface Blow-Around 211\u003c\/p\u003e \u003cp\u003eMicroscopic Defects 211\u003c\/p\u003e \u003cp\u003eStarry Night 211\u003c\/p\u003e \u003cp\u003ePinholes 212\u003c\/p\u003e \u003cp\u003eThe Role of Dryer Simulation in Troubleshooting 212\u003c\/p\u003e \u003cp\u003eThe Role of Radiative Heating in Defect Reduction 214\u003c\/p\u003e \u003cp\u003eReferences 215\u003c\/p\u003e \u003cp\u003e\u003cb\u003e11 Problems Associated with Web Handling 217\u003cbr\u003e \u003c\/b\u003eby \u003ci\u003eGerald I. Kheboian\u003c\/i\u003e\u003c\/p\u003e \u003cp\u003eWeb 218\u003c\/p\u003e \u003cp\u003eWeb Characteristics and Problems Associated with the Web 219\u003c\/p\u003e \u003cp\u003eBase Web Defects that Cause Wrinkling 219\u003c\/p\u003e \u003cp\u003eCauses of Web Defects 221\u003c\/p\u003e \u003cp\u003eWeb Attributes 221\u003c\/p\u003e \u003cp\u003eWeb Camber 221\u003c\/p\u003e \u003cp\u003eWeb Cross-Machine Thickness Profile Variation 223\u003c\/p\u003e \u003cp\u003eBasis Weight Profile Variation 225\u003c\/p\u003e \u003cp\u003eSurface of the Web 225\u003c\/p\u003e \u003cp\u003ePlastic Web 227\u003c\/p\u003e \u003cp\u003eWeb Transport Systems 228\u003c\/p\u003e \u003cp\u003eTension 230\u003c\/p\u003e \u003cp\u003eReasons Why Operators Must Change Tensions in Order to Successfully Transport Web 231\u003c\/p\u003e \u003cp\u003eUnwind Stand 231\u003c\/p\u003e \u003cp\u003eWhen to Use Drive Motors on an Unwind Stand 233\u003c\/p\u003e \u003cp\u003eWeb Control 234\u003c\/p\u003e \u003cp\u003eCore Selection and Build-Down Ratio 235\u003c\/p\u003e \u003cp\u003eDraw Rolls Pull Rolls Capstans 235\u003c\/p\u003e \u003cp\u003eWeb Slippage and What Slip Affects 235\u003c\/p\u003e \u003cp\u003eNip Rolls 236\u003c\/p\u003e \u003cp\u003eUnnipped Rolls (Elastomer Rolls) 237\u003c\/p\u003e \u003cp\u003eSuction Rolls 241\u003c\/p\u003e \u003cp\u003eSuction Aprons or Tables 242\u003c\/p\u003e \u003cp\u003eIncreasing the Reliability of Draw Roll Sections 243\u003c\/p\u003e \u003cp\u003eTension Isolation 243\u003c\/p\u003e \u003cp\u003eDifferential Tension 244\u003c\/p\u003e \u003cp\u003eDriving Web-Carrying Rolls Within a Dryer 245\u003c\/p\u003e \u003cp\u003eThe Rewinder 246\u003c\/p\u003e \u003cp\u003eUse of Accumulators at the Rewind and Unwind 246\u003c\/p\u003e \u003cp\u003eSurface\/Center Rewinds 247\u003c\/p\u003e \u003cp\u003eCenter-Driven Winders 248\u003c\/p\u003e \u003cp\u003eDrives for Laminators 248\u003c\/p\u003e \u003cp\u003eWhen to Drive Both Laminator Rolls 249\u003c\/p\u003e \u003cp\u003eCoating Roll Drives 249\u003c\/p\u003e \u003cp\u003eCoating Defects—Sources and Some Solutions 249\u003c\/p\u003e \u003cp\u003eBacklash Exists in Timing Belts Gearboxes and Geared Couplings 250\u003c\/p\u003e \u003cp\u003eChatter Caused by the Roll 251\u003c\/p\u003e \u003cp\u003eRoll Unbalance 251\u003c\/p\u003e \u003cp\u003eNonconcentric Rolls 252\u003c\/p\u003e \u003cp\u003eCoating Roll Drive Systems 252\u003c\/p\u003e \u003cp\u003eFeedback Devices 254\u003c\/p\u003e \u003cp\u003eCoating Supply System 254\u003c\/p\u003e \u003cp\u003eTransmission of Vibration Through Structural Members to the Coating Stand 254\u003c\/p\u003e \u003cp\u003eEffect of Dryer Design on Coating Quality 255\u003c\/p\u003e \u003cp\u003eTroubleshooting ‘‘Sudden’’ Coating Problems 255\u003c\/p\u003e \u003cp\u003eMonitoring Speeds and Tensions of Web 257\u003c\/p\u003e \u003cp\u003eA Speed Monitoring System 257\u003c\/p\u003e \u003cp\u003eMonitoring the Speed of Idler Rolls 257\u003c\/p\u003e \u003cp\u003eMonitoring for Slip Conditions on High-Speed Coaters 258\u003c\/p\u003e \u003cp\u003eTension Monitoring Systems 258\u003c\/p\u003e \u003cp\u003eSpecifying the Tension Range 259\u003c\/p\u003e \u003cp\u003eWhy Is Tension Control Needed? 259\u003c\/p\u003e \u003cp\u003eEffects of Wiring Practices on Tension Control 260\u003c\/p\u003e \u003cp\u003eWhen Do You Use a Pure Speed Control? 261\u003c\/p\u003e \u003cp\u003eEquipment Lists Avoid Problems and Help Plant Personnel 264\u003c\/p\u003e \u003cp\u003eFrequency and Direction of a Speed Perturbation 265\u003c\/p\u003e \u003cp\u003eProblems that Occur After the Machine Is in Production 266\u003c\/p\u003e \u003cp\u003eTypes of Tension Control Systems 266\u003c\/p\u003e \u003cp\u003eMotor Current Regulation 268\u003c\/p\u003e \u003cp\u003eDancer Roll Control 268\u003c\/p\u003e \u003cp\u003eExample of the Use of a Dancer in Close Proximity to an Air Roll 270\u003c\/p\u003e \u003cp\u003eUsing Air Roll Air Gap Control as a Dancer in the Dryer 270\u003c\/p\u003e \u003cp\u003eForce Transducer Control 272\u003c\/p\u003e \u003cp\u003eSizing Strain Gauge Load Cells 274\u003c\/p\u003e \u003cp\u003eSection Characteristics that Ensure Good Web Transport Control 274\u003c\/p\u003e \u003cp\u003eMaster or Lead Section 274\u003c\/p\u003e \u003cp\u003eUsing Load Cell Control in Close Proximity to an Air Roll 275\u003c\/p\u003e \u003cp\u003eDefects that Occur When the Master Section Slips 275\u003c\/p\u003e \u003cp\u003eSections with Limited Ability to Control Web Transport or Tension 275\u003c\/p\u003e \u003cp\u003eDealing with Sections that Have Limited Ability to Control Tension 276\u003c\/p\u003e \u003cp\u003eSections that Always Slip or Almost Always Slip 277\u003c\/p\u003e \u003cp\u003eDrive Features that Give the Operator Additional Tools 278\u003c\/p\u003e \u003cp\u003eTools that Are Used for Troubleshooting Drive Problems 278\u003c\/p\u003e \u003cp\u003eOptical Alignment Tooling and Laser Technology 278\u003c\/p\u003e \u003cp\u003eMachine Alignment: Avoiding Many Web Handling Problems 278\u003c\/p\u003e \u003cp\u003eExperience: Dryers Installed with the Dryer Centerline Skewed from the Machine Centerline 279\u003c\/p\u003e \u003cp\u003eAlignment Problems Due to Building Location in a Swamp or Tidal River 279\u003c\/p\u003e \u003cp\u003eThe Alignment Process 280\u003c\/p\u003e \u003cp\u003eThe Baseline 281\u003c\/p\u003e \u003cp\u003eChecking the Alignment of a Size Press (Roll Coater) on a Paper Web 282\u003c\/p\u003e \u003cp\u003eKnowing How Your Machine Operates Can Avoid Problems in the Future 283\u003c\/p\u003e \u003cp\u003eSummary 284\u003c\/p\u003e \u003cp\u003eReferences and Bibliography 284\u003c\/p\u003e \u003cp\u003e\u003cb\u003e12 The Role of Process Support Equipment 287\u003c\/b\u003e\u003c\/p\u003e \u003cp\u003eIntroduction 287\u003c\/p\u003e \u003cp\u003eDefinitions 288\u003c\/p\u003e \u003cp\u003eDefect Support Equipment Interactions 291\u003c\/p\u003e \u003cp\u003eSupport Equipment Effect on Defects 291\u003c\/p\u003e \u003cp\u003eMechanical Chatter 291\u003c\/p\u003e \u003cp\u003eSerpentine Chatter 292\u003c\/p\u003e \u003cp\u003ePoor Physical Uniformity 294\u003c\/p\u003e \u003cp\u003eRibbing 294\u003c\/p\u003e \u003cp\u003eBubbles 294\u003c\/p\u003e \u003cp\u003eContamination Spots 294\u003c\/p\u003e \u003cp\u003eLow Overall Productivity 295\u003c\/p\u003e \u003cp\u003eDefects Due to Static Electricity 295\u003c\/p\u003e \u003cp\u003eScratches 295\u003c\/p\u003e \u003cp\u003eStreaks 296\u003c\/p\u003e \u003cp\u003eMottle 296\u003c\/p\u003e \u003cp\u003eCoating Weight Nonuniformity in Premetered Applicators 297\u003c\/p\u003e \u003cp\u003eCoating Weight Nonuniformity in Self-Metered and Doctor Coaters 297\u003c\/p\u003e \u003cp\u003eAir Bar Rubs in a Floater Dryer 297\u003c\/p\u003e \u003cp\u003eDry Point Variability 298\u003c\/p\u003e \u003cp\u003eSelection of Equipment 298\u003c\/p\u003e \u003cp\u003e\u003cb\u003e13 Coating Defects Database 299\u003c\/b\u003e\u003c\/p\u003e \u003cp\u003eNeed for Coating Defects Database 299\u003c\/p\u003e \u003cp\u003eDefects Database: Examples 302\u003c\/p\u003e \u003cp\u003eBase Flake 303\u003c\/p\u003e \u003cp\u003eRoll Repeats 303\u003c\/p\u003e \u003cp\u003eBubbles 303\u003c\/p\u003e \u003cp\u003eBacteria Bubbles 306\u003c\/p\u003e \u003cp\u003eAimcal Defects Lexicon: Guide to Web Coating Technology 306\u003c\/p\u003e \u003cp\u003eDescription of Lexicon 306\u003c\/p\u003e \u003cp\u003eNeed for Lexicon 306\u003c\/p\u003e \u003cp\u003eLexicon Overview 308\u003c\/p\u003e \u003cp\u003eLexicon Sections 308\u003c\/p\u003e \u003cp\u003eGlossary 308\u003c\/p\u003e \u003cp\u003eTroubleshooting Guide 309\u003c\/p\u003e \u003cp\u003eDefect Image Section 310\u003c\/p\u003e \u003cp\u003eSearch Capability 310\u003c\/p\u003e \u003cp\u003eAvailability 312\u003c\/p\u003e \u003cp\u003eReferences 314\u003c\/p\u003e \u003cp\u003e\u003cb\u003e14 Defect Prevention 315\u003c\/b\u003e\u003c\/p\u003e \u003cp\u003eIntroduction 315\u003c\/p\u003e \u003cp\u003eDefine Product and Process Requirements 316\u003c\/p\u003e \u003cp\u003eEnsure Availability of Valid Analytical Techniques 319\u003c\/p\u003e \u003cp\u003eEnsure Web Coating Process Meets Specifications 319\u003c\/p\u003e \u003cp\u003eUse Appropriate Coating Method 320\u003c\/p\u003e \u003cp\u003eDevelop and Implement Operational Procedures 321\u003c\/p\u003e \u003cp\u003eQuantify and Understand Defect Losses 321\u003c\/p\u003e \u003cp\u003eUse Structured Troubleshooting Protocol 325\u003c\/p\u003e \u003cp\u003eUse Computer Database to Store and Share Information 325\u003c\/p\u003e \u003cp\u003eImplement Improved Process Technology 327\u003c\/p\u003e \u003cp\u003eUse Statistical Process Control 327\u003c\/p\u003e \u003cp\u003eDevelop Fundamental Process Understanding 328\u003c\/p\u003e \u003cp\u003eIndex 331\u003c\/p\u003e","brand":"John Wiley \u0026 Sons Inc","offers":[{"title":"Default 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