Epoxy resin is a widely used high-performance material, commonly used in coatings, gluing agents, composites and electronic packaging. In order to ensure the uniformity and performance of the coating layer, the choice of film process and the use of equipment are crucial. As a High Accuracy film equipment, drawdown blade Film Applicator can effectively improve the mass and conformity of epoxy resin film. This article will discuss in detail the working principle, operation process and selection points of epoxy resin drawdown blade Film Applicator.
Drawdown blade Film Applicator is a device that uniformly coats the surface of the substrate by controlling the Spreader head and Spreader parameters. Its core principle is to use the mechanical force of the drawdown blade to Spreader the liquid epoxy resin on the substrate at a set thickness and speed to form a uniform film. The specific principle is as follows:
Spreader head and drawdown blade: The Spreader head is responsible for supplying epoxy resin to the front end of the drawdown blade, and the drawdown blade scrapes the epoxy resin evenly on the surface of the substrate through mechanical force. The material of the drawdown blade is usually wear-resistant stainless steel to ensure accuracy and durability in long-term use.
Spreader thickness control: The thickness of the Spreader is determined by the gap between the drawdown blade and the substrate. By adjusting the height and pressure of the drawdown blade, the thickness of the Spreader can be precisely controlled to ensure the uniformity of the coating.
Spreader speed control: Spreader speed control is critical for film mass. Too fast speed may result in uneven or blistering coatings, and too slow speed may result in coatings that are too thick or sagging. Drawdown blade Film Applicators are usually equipped with variable frequency governors or servo motors for stepless speed regulation and precise control.
Substrate Fixing and Conveying: In order to ensure the Stability of the Spreader process, the substrate needs to be fixed or continuously transported. Common fixing methods include Vacuum chuck and fixture fixing, and conveying methods include drum conveying and belt conveying.
The operation process of epoxy resin drawdown blade Film Applicator includes four main steps: Preparation, Spreader, curing and cleaning.
Step 1 Prepare
Spreader epoxy resin requires adequate preparation:
Substrate preparation: Select the appropriate substrate (such as Glass, Metal, Plastic, etc.) and ensure that the surface of the substrate is clean, flat, and free of oil and dust.
Epoxy resin preparation: Select the appropriate epoxy resin according to the application requirements, and mix and defoaming according to the manufacturer's instructions. Ensure the uniformity and applicable viscosity of the epoxy resin.
Equipment Inspection: Check the various components of the drawdown blade Film Applicator, including drawdown blade, Spreader head, substrate fixture and Control system, to ensure that the equipment is in normal working condition.
2. Spreaders
The Spreader process is the core step of the drawdown blade Film Applicator operation:
Mounting substrate: Fix the substrate on the Spreader stage to ensure it is flat and stable. If using Vacuum chuck, check the working condition of the vacuum system.
Adjust drawdown blade: Adjust the gap between the drawdown blade and the substrate according to the required Spreader thickness. The drawdown blade height can be precisely set by the fine-tuning mechanism or the numerical control system.
Set Spreader parameters: Set parameters such as Spreader speed, drawdown blade pressure and application length. Reasonable adjustment according to the characteristics of epoxy resin and process requirements.
Start the Spreader: Start the drawdown blade Film Applicator to ensure that the Spreader head is evenly supplied with epoxy resin and evenly coated on the surface of the substrate through the drawdown blade. During the process, the Spreader mass needs to be monitored and the parameters adjusted in time to ensure the conformity of the coating.
3. Curing
After the epoxy resin Spreader is completed, it needs to be cured:
Preliminary curing: Preliminary curing at room temperature to make the epoxy resin coating curing to a movable state. Preliminary curing time depends on the type of epoxy resin and Ambient Temperature.
Complete curing: Place the initially cured substrate in an oven or Miscellaneous heating equipment and perform complete curing according to the curing process requirements of epoxy resin. Usually the temperature is between 60-150 ° C, and the curing time ranges from several hours to tens of hours.
Chill down: After curing, it is necessary to gradually chill down to room temperature to avoid sharp chill down resulting in coating cracking or peeling.
Step 4: Cleaning
After the Spreader is finished, the equipment needs to be cleaned to ensure the accuracy and effect of the next use:
Drawdown blade cleaning: Remove the drawdown blade and clean it with appropriate solvent to ensure no residual epoxy resin. The cleaning process is more convenient if the clamshell drawdown blade is used.
Spreader head cleaning: Spreader head and its pipes are cleaned to prevent epoxy resin curing blockage.
Equipment maintenance: check the abrasion of all parts of the equipment, carry out necessary maintenance and maintenance.
Choosing the right epoxy resin drawdown blade Film Applicator requires comprehensive consideration of various factors to meet specific application requirements.
1. Spreader accuracy
Spreader accuracy is a key indicator of drawdown blade Film Applicators, which directly affects the uniformity and performance of coatings. Equipment with High Accuracy Control system should be selected to ensure the uniformity and conformity of Spreader thickness.
Drawdown blade accuracy: drawdown blade accuracy should reach +/- 0.001mm to ensure High Accuracy Spreader requirements.
Film thickness control: Equipped with differential regulator or numerical control system to ensure that Spreader thickness can be accurately adjusted.
2. Spreader speed
Select the appropriate Spreader speed range according to the process requirements to ensure the Stability and efficiency of the film process.
Speed range: Usually, the Spreader speed can be adjusted within the range of 1-300mm/s, and the appropriate speed range can be selected according to specific needs.
Speed regulation mode: using stepless speed regulation or servo motor control to achieve accurate speed regulation.
3. Substrate compatibility
Select the drawdown blade Film Applicator for different substrates according to the application scenario to ensure that the Substrate clamping method and the coating table material are adapted.
Fixing method: Vacuum chuck and fixture fixing are common Substrate clamping methods, choose the appropriate fixing method according to the type of substrate.
Coating table: Glass plate, stainless steel plate and other materials are commonly used as coating table, which needs wear resistance and corrosion resistance.
4. Ease of operation
The ease of operation directly affects the production efficiency and the working experience of the operator, and the equipment with friendly Operating interface and convenient cleaning should be selected.
Control Panel: The Touchscreen control panel is simple and intuitive to operate, making it easy to set and monitor parameters.
Cleaning design: clamshell drawdown blade design for easy cleaning, reduce maintenance time.
5. Additional features
Select a drawdown blade Film Applicator with additional functions according to specific needs to meet different process requirements.
Heating function: For processes that require Spreader at a specific temperature, the heating function ensures the Stability of the Spreader process.
Vacuum chuck: Vacuum chuck function can ensure that the substrate is flat and fixed, improve Spreader accuracy.
The following are two examples of epoxy resin drawdown blade Film Applicators in practical applications, showing different selection and operation strategies.
Case 1: Research on University Laboratory Spreader
A University Materials Science Research Laboratory needs to conduct epoxy resin Spreader research and selects a High Accuracy drawdown blade Film Applicator. The equipment has the following characteristics:
High Accuracy drawdown blade, Spreader thickness accuracy of +/- 0.001mm;
Equipped with differential regulator, high film thickness control accuracy;
Touchscreen control panel, simple and intuitive operation;
Vacuum chuck function to ensure that the substrate is fixed flat.
Through this equipment, the laboratory has successfully realized the accurate Spreader of various epoxy resin formulations, and carried out coating performance research, and achieved remarkable scientific research results.
Case 2: New material research and development center
A New materials R & D center needed to develop new epoxy resin coatings that required high flexibility and versatility. A multifunctional drawdown blade Film Applicator was selected with the following characteristics:
Multifunctional Spreader: with bar Spreader and Blade Coating functions, can be flexibly switched according to different coating requirements;
Wide range of applications: Spreader for various substrates (such as Glass, cardboard, fabric, etc.)
Easy cleaning design: clamshell drawdown blade and Modular design for easy cleaning and maintenance;
Adjustable parameters: application length, speed and thickness can be freely adjusted to meet a variety of Spreader process requirements.
The center has successfully developed a variety of new epoxy resin coating materials using this equipment, and applied them to high-tech fields such as aerospace and electronic packaging.
In the process of using epoxy resin drawdown blade Film Applicator, you may encounter some FAQs. Here are a few typical problems and their solutions.
1. Coating thickness uneven
Problem description: Coating thickness unevenness will affect the coating performance, resulting in unstable product mass.
Solution:
Check the drawdown blade height: ensure that the gap between the drawdown blade and the substrate is uniform, and fine-tune if necessary;
Adjust Spreader speed: Adjust Spreader speed according to the viscosity and rheology of epoxy resin to avoid too fast or too slow;
Uniform feeding: Ensure uniform feeding of the Spreader head to avoid accumulation or loss of Coatings at the front end of the drawdown blade.
2. intercoat blistering
Problem description: Intercoating blistering can affect the Smoothness and performance of the coating, resulting in poor use.
Solution:
Defoaming treatment: Spreader before the epoxy resin fully defoaming treatment to reduce the generation of bubbles;
Control Spreader speed: appropriately reduce Spreader speed to reduce bubble formation;
Use Vacuum chuck: Vacuum chuck is used in the substrate fixing process to ensure that the substrate surface is flat and reduce the chance of bubble generation.
3. Coating hanging
Problem description: Coating sagging can cause uneven coating thickness and affect the final product mass.
Solution:
Adjust Spreader thickness: Adjust Spreader thickness according to the viscosity of epoxy resin to avoid too thick Spreader;
Control Spreader speed: appropriately reduce Spreader speed to reduce sagging phenomenon;
Optimize the formula: adjust the formula of epoxy resin, improve its leveling and viscosity, and reduce sagging.
4. Equipment cleaning is difficult
Problem description: After the Spreader is over, the equipment is difficult to clean, which affects the accuracy and effect of the next use.
Solution:
Easy to use design: choose equipment with clamshell drawdown blade and Modular design for easy cleaning and maintenance;
Regular maintenance: regular cleaning and maintenance of equipment to prevent epoxy resin curing blockage;
Use suitable solvent: Select the appropriate solvent for cleaning according to the characteristics of the epoxy resin to ensure no residue.
With the continuous expansion of epoxy resin Applications and the continuous advancement of technology, drawdown blade Film Applicators are also evolving. Here are some future trends:
1. Intelligent control
Future drawdown blade Film Applicators will be more intelligent, equipped with advanced Sensors and Control systems to achieve real-time monitoring and automatic adjustment of the Spreader process, improving Spreader accuracy and efficiency.
2. Multi-functional integration
Multifunctional drawdown blade Film Applicators will become the trend, capable of simultaneously performing a variety of Spreader processes, such as bar Spreader, Blade Coating, lame plating, etc., to meet different Spreader needs and improve the applicability and flexibility of the equipment.
3. Environmental protection and energy saving
Environmental protection and energy saving will be the development focus of future drawdown blade Film Applicators. Using low energy consumption design and environmentally friendly materials to reduce energy consumption and environment pollution meets the requirements of green manufacturing.
4. High Accuracy Spreader
With the development of High Accuracy manufacturing technology, the requirements for Spreader accuracy will continue to increase. Future drawdown blade Film Applicators will use more advanced control technologies and materials to improve Spreader accuracy and conformity to meet the needs of High Accuracy manufacturing.
Epoxy resin drawdown blade Film Applicator, as a High Accuracy Spreader device, plays an important role in epoxy resin Spreader. By understanding its Working Principle, operation process and selection points, film mass and production efficiency can be effectively improved. In the future, with the continuous advancement of technology, drawdown blade Film Applicator will make greater development in intelligent, multi-functional, environmentally friendly and energy-saving and High Accuracy Spreader, providing stronger support for Spreader applications in various industries.
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