2018 David Roisum, Ph.D. Finishing Technologies, Inc.
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1 Web SM What Coaters Need to Know About Winders Ba c k Defect Front Sup ply Proc ess Produc t 2018 David Roisum, Ph.D. Finishing Technologies, Inc. 89.1
2 #1 Thing Is that Lorem ipsum dolor sit amet, consectetur adipiscing elit. Nulla turpis nulla, rutrum vel dolor sodales, aliquet iaculis elit. Proin placerat leo a dictum placerat. Duis sed ante vitae ipsum euismod sagittis. Proin tristique consequat rhoncus. Integer in mi vitae ipsum vestibulum congue quis at erat. Sed viverra lacus nec porta tincidunt. Vivamus odio mi, vehicula id pharetra vitae, venenatis eget odio. Suspendisse id placerat metus, in consectetur turpis. Vivamus viverra sapien ultricies, condimentum risus ac, vestibulum sapien. Aenean mollis fermentum diam, vel iaculis arcu rutrum et. Curabitur ac rhoncus est. Vivamus nec pellentesque est, non aliquet dolor. Curabitur faucibus condimentum est, et sagittis velit venenatis pretium. Proin pellentesque euismod arcu, a porttitor neque faucibus at. Mauris eget magna odio. Donec pulvinar id nisi et maximus. Sed tincidunt tortor ut tristique feugiat. Vivamus eget libero sit amet nulla viverra imperdiet in nec eros. Vivamus sem erat, pellentesque sit amet libero vitae, dictum vulputate tortor. Sed nisl magna, tempor a ipsum sit amet, finibus lacinia enim. Donec commodo vestibulum nulla nec malesuada. Etiam lobortis, turpis sit amet hendrerit rutrum, nibh magna pharetra turpis, eleifend vestibulum lectus sapien vitae dolor. Curabitur sed orci maximus risus interdum volutpat. Fusce ultrices semper venenatis. Curabitur ut dolor volutpat, sagittis dui placerat, feugiat mi. Proin leo purus, sagittis at nisi sed, cursus viverra dolor. Praesent consectetur ipsum quis augue fringilla, at bibendum nibh commodo. Vestibulum nec scelerisque eros. Morbi fermentum ex diam, quis iaculis nibh ultrices vitae. Phasellus nisi odio, varius at magna ac, ornare scelerisque augue. Donec mattis viverra elit, a maximus tortor porta quis. Duis fringilla rhoncus augue. Nullam porttitor pulvinar leo nec imperdiet. Sed auctor leo quis nunc volutpat lobortis. Aliquam vitae bibendum ante, a pulvinar lectus. In dolor eros, dictum id consequat non, ullamcorper non sapien. Phasellus tristique nunc quis nulla euismod vehicula. Ut eget ipsum posuere, dapibus justo vel, aliquet est. Suspendisse elementum nibh et tortor hendrerit varius. Mauris vel turpis suscipit, luctus mi fringilla, fringilla risus. Nulla rhoncus ultrices tellus a lobortis. Integer cursus elit in sodales volutpat. Cras ac tortor quis quam posuere vestibulum. Praesent ullamcorper fringilla ipsum, nec mattis leo volutpat nec. Vestibulum efficitur, nulla non pretium euismod, magna justo tincidunt sem, eu viverra ex metus nec ante. In tristique venenatis elit, eu molestie est maximus a. Integer porta nec justo id blandit. Vestibulum iaculis erat vel urna porttitor eleifend. Nulla nulla elit, ullamcorper vel neque sit amet, ultricies semper purus. Mauris congue leo vitae eros auctor, sit amet sodales justo consequat. Maecenas lacinia suscipit vehicula. 89.2
3 #2 Thing Almost as important is that Lorem ipsum dolor sit amet, consectetur adipiscing elit. Nulla turpis nulla, rutrum vel dolor sodales, aliquet iaculis elit. Proin placerat leo a dictum placerat. Duis sed ante vitae ipsum euismod sagittis. Proin tristique consequat rhoncus. Integer in mi vitae ipsum vestibulum congue quis at erat. Sed viverra lacus nec porta tincidunt. Vivamus odio mi, vehicula id pharetra vitae, venenatis eget odio. Suspendisse id placerat metus, in consectetur turpis. Vivamus viverra sapien ultricies, condimentum risus ac, vestibulum sapien. Aenean mollis fermentum diam, vel iaculis arcu rutrum et. Curabitur ac rhoncus est. Vivamus nec pellentesque est, non aliquet dolor. Curabitur faucibus condimentum est, et sagittis velit venenatis pretium. Proin pellentesque euismod arcu, a porttitor neque faucibus at. Mauris eget magna odio. Donec pulvinar id nisi et maximus. Sed tincidunt tortor ut tristique feugiat. Vivamus eget libero sit amet nulla viverra imperdiet in nec eros. Vivamus sem erat, pellentesque sit amet libero vitae, dictum vulputate tortor. Sed nisl magna, tempor a ipsum sit amet, finibus lacinia enim. Donec commodo vestibulum nulla nec malesuada. Etiam lobortis, turpis sit amet hendrerit rutrum, nibh magna pharetra turpis, eleifend vestibulum lectus sapien vitae dolor. Curabitur sed orci maximus risus interdum volutpat. Fusce ultrices semper venenatis. Curabitur ut dolor volutpat, sagittis dui placerat, feugiat mi. Proin leo purus, sagittis at nisi sed, cursus viverra dolor. Praesent consectetur ipsum quis augue fringilla, at bibendum nibh commodo. Vestibulum nec scelerisque eros. Morbi fermentum ex diam, quis iaculis nibh ultrices vitae. Phasellus nisi odio, varius at magna ac, ornare scelerisque augue. Donec mattis viverra elit, a maximus tortor porta quis. Duis fringilla rhoncus augue. Nullam porttitor pulvinar leo nec imperdiet. Sed auctor leo quis nunc volutpat lobortis. Aliquam vitae bibendum ante, a pulvinar lectus. In dolor eros, dictum id consequat non, ullamcorper non sapien. Phasellus tristique nunc quis nulla euismod vehicula. Ut eget ipsum posuere, dapibus justo vel, aliquet est. Suspendisse elementum nibh et tortor hendrerit varius. Mauris vel turpis suscipit, luctus mi fringilla, fringilla risus. Nulla rhoncus ultrices tellus a lobortis. Integer cursus elit in sodales volutpat. Cras ac tortor quis quam posuere vestibulum. Praesent ullamcorper fringilla ipsum, nec mattis leo volutpat nec. Vestibulum efficitur, nulla non pretium euismod, magna justo tincidunt sem, eu viverra ex metus nec ante. In tristique venenatis elit, eu molestie est maximus a. Integer porta nec justo id blandit. Vestibulum iaculis erat vel urna porttitor eleifend. Nulla nulla elit, ullamcorper vel neque sit amet, ultricies semper purus. Mauris congue leo vitae eros auctor, sit amet sodales justo consequat. Maecenas lacinia suscipit vehicula. 89.3
4 Questions? Answers: David Roisum, Ph.D office cell 89.4
5 #1 Thickness Profile Profile is the variation of something across the width of the web That something could be thickness related such as basis weight, caliper, gage, coat weight T total = t substrate + t coating 89.5
6 #1 Thickness Profile - Range Range 1% - few problems* 10% - few products* Winder is a Customer *Nonwovens, textiles, tissue and blown film (oscillated fast enough) can take a bit more *metal foil can t even take that much 89.6
7 Thickness Profile Problems Caused by basis weight, caliper, thickness variations Bagginess (stretching over gage bands) Corrugations Ridges Tin Canning (across part of roll) Starring (one side of roll) Wrinkles (produced on the wound roll) Made worse by BW, caliper, thickness variations All tight, loose and taper defects 89.7
8 How Much is TOO Much Bagginess? Paper estimation example Paper breaks at 1% Paper yields a bit with time at 0.1% strain Max delta diameter = (1/1000) x 40 = 0.040, 20 mils on radius See Cecilia Land PhD thesis Some foil laminates damaged with (250 micron) radius difference Diameter Diameter Translates to approximately 1% variation few problems 10% variation few customers 89.8
9 Screening Bad Rolls 1 Q: Why not check scanners or test labs? A: Often not good enough to satisfy winder Consider trying to measure a 1% variation of a (25 micron) thick web with confidence. That requires seeing a few millionths of an inch or the wavelength of UV light. 89.9
10 Screening Bad Rolls 2 Another way: Roll Hardness measures hundreds of layers with a single whack. Even then Percent Probability of Running without Wrinkling Range of Lanes Average Roll Hardness Percent < > Figure Courtesy of Amy Thuer of Avery Dennison from her paper Using Roll Hardness to Screen for Excessive Web Bagginess. IWEB13 Web Baggy Web Screening 89.10
11 Profile Coarse Scale Taper Smile Frown Caliper Caliper Caliper Taper CD Position Smile CD Position Frown CD Position 89.11
12 Profile Fine Scale Ridge Valley Step Caliper Caliper Caliper Ridge CD Position Valley CD Position Step CD Position 89.12
13 #2 Web-Web COF Coefficient Of Friction Concepts COF is a property of a PAIR of surfaces (a single surface is sound of one hand clapping) Relevant property is Web-Web COF A to B sides Under similar pressures etc (Coulomb friction is just an approximation) 89.13
14 COF too Low - Telescoping IA - Winding core supported roll 89.14
15 COF too High Example grades PSA adhesives Nonwovens, textiles, tissue, Out-of-round Rolls Winder vibration at higher speeds Self-Excitation (ever increasing amplitudes) m direction Spring/Ma ss Syste m k Deformable Surface wa velength path Daly, David A. How paper rolls on a winder generate vibration and bouncing Paper Trade J, pp 48-51, Dec 11,
16 COF tends to decrease with time Migration of slip agent molecules to the surface of film Migration of waxes and other agents on some coatings and printing inks Paper COF decreases with time for reasons not yet known You may be able to wind a roll That your customer can not unwind 89.16
17 Bottom Line - DFM Design For Manufacturability You can do anything you want with each ply and each coating, however: The total thickness must be level enough The outer molecule belongs to the winder because that determines COF 89.17
18 Questions? And, after all this, you still want to coat? Answers: David Roisum, Ph.D office cell 89.18
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