electron beam technology for converting applications · background: electron beam equipment...
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Electron Beam Technology for Converting Applications
Stephen C. Lapin, Ph.D.PCT Engineered Systems, LLC
Davenport, IA
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Background:Electron Beam Technology
Accelerated electrons generated by electrically operated filamentsEnergy of electrons determined by acceleration potential
Low voltage typically defined as less than 300 kVPenetration determined by voltage and substrate density
Electrons will ionize most organic and polymer materialsMaking and breaking of chemical bonds is the basis for crosslinking and curing (polymerization)Typical applied energy (dose)
Crosslinking: 25 to 150 kGy (2.5 to 15 Mrads)Curing: 20 to 40 kGy (2 to 4 Mrads)
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Background:Electron Beam Equipment
Industrial processorsIn use for more than 30 yearsOperates up to 300 kVWeb widths up to 130 inchesThroughput up to 5000 MRFPM (5 Mrads @ 1000 ft/min)
New generation lower voltage processorsOperates at 70 to 125 kVLower cost and smaller size compared to original industrial equipmentIdeal for many printing, packaging, and converting applicationsThroughput up to 3600 MRFPM (3 Mrads @ 1200 ft/min)
New compact modular processorsModular 10 and 16 inch wide emittersOperates at 70 to 150 kVPermanent vacuumSurface sterilization applicationsPotential for narrow web applications
Scanning beam processors – limited use in web applications
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Electron Beam Equipment
Industrial Electron Beam Processor New Generation Low VoltageElectron Beam Processor
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Electron Beam Advantages
Lower energy usage compared to thermal dryingSmall footprintNear zero VOCsInstantaneous curingHigh line speedsConsistent outputImproved product performance
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UV/EB ComparisonUV
Photoinitiator required for curingSurface curing in air or inert atmosphereLight penetration needed for curingMultiple lamps needed for wide/high speed processingHigh heat output from mercury lampsOutput variation with age and across width of lamp
EBNo photoinitiator neededSurface curing requires inert (N2) atmosphere (not need for laminate processes)Penetrates opaque materialsSingle EB unit will cure >100 inches wide at >1000 ft/minCooler, more energy efficient processConsistent output and uniformity
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Low Voltage ElectronBeam Applications
Printing and Packaging ApplicationsInk curing: web off-set, flexo (WetflexTM)Overprint Coatings: laminate replacement, cold seal release, multi-wall paper bags, outdoor film bagsLaminating Adhesives: folding cartons, flexible packaging
Converting ApplicationsNon-printing applicationsMay include converting of substrates that are subsequently printed
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Electron Beam Ink CuringWeb Offset Carton Production
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EB Converting Applications
Film CrosslinkingPressure Sensitive Adhesive CrosslinkingDirect CoatingLaminatingTransfer CoatingBackside EmbossingTopside Embossing
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Film CrosslinkingELECTRON
BEAM
UNWIND(or direct from
film production)REWIND
TREATED FILM
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Film CrosslinkingLargest single EB applicationPolyethylene and polyethylene copolymers are well known to undergo crosslinking upon EB irradiationOther polymers may undergo chain scission or a combination of scission and crosslinking depending on the polymerMost common use of polymer crosslinking is to create heat shrinkable filmsCrosslinking is also be used to modify the physical and thermal properties of various films
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Pressure SensitiveAdhesive Crosslinking
ELECTRON BEAM
UNWIND REWIND
OPTIONALRELEASE
LINEREXTRUDER
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Pressure SensitiveAdhesive Crosslinking
Hot melt, syrups, solvent, and water based PSA’s may be EB crosslinkedEB Crosslinking of hot melt adhesives improves sheer, heat, and chemical resistanceEB crosslinked hot melt PSAs provide alternative to solvent acrylic PSAsApplications include free film adhesives, high performance tapes, and label stock
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Direct CoatingELECTRON
BEAM
UNWINDCOATER
REWIND
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Direct CoatingRelease coatings
Premium silicone release liners for PSAsIndustrial release coatings (silicone and non-silicone)
Coatings for vacuum metallizationPremetallization primersMetal protective coatings
Enhance/preserve barrier propertiesCorrosion protection
Protective coatingsFurniture and countertop laminatesCrosslinking provides stain and scratch resistance
Pigmented and filled coatingsEB penetrates opaque coatingsExamples: magnetic media, abrasive binders
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Adhesive Laminating
ELECTRON BEAM
PRIMARYUNWIND
COATERREWIND
SECONDARYUNWIND
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Adhesive LaminatingEB advantages
Stable one component adhesivesRoom temperature applicationWill cure through opaque filmsInstant bonding – immediate QC, slitting, die cutting, shipping
Current commercial packaging applicationsFlexible packaging (film-to-film and film-to-paper)Folding cartons (film-to-paperboard)
Converting applicationsPaperboard and plastic card stock - lamination of metalized, holographic, and specialty films Paper, film, and foil – prelaminated packaging and industrial substratesInstant bonding enable in-line laminating with other converting processes
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Transfer Coating
ELECTRON BEAM
PRIMARYUNWIND
TRANSFERADHESIVE
PRECOATEDCARRIER
CARRIERREWIND
TRANSFERCOATEDREWIND
SECONDARYUNWIND
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Transfer CoatingEB advantages
No solvent or water to dryCool process allows transfer to heat sensitive substratesLow adhesive weightsInstant curingPermanent bond
ApplicationsTransfer metalliztionDecorative and specialty transfer coatingsPattern printing of adhesive produces transfer pattern (no stamping dies required)Highly uniform surface defined by casting on the original carrier film
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Backside Embossing
ELECTRON BEAM
EMBOSSEDDRUM
COATERREWINDUNWIND
EMBOSSEDPATTERN
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Backside EmbossingEB advantages
No solvent or water to dryCure through opaque materials including paperClean release from embossed metal drumPattern reproduction more accurate than thermal embossingWide feature size (from microns to inches)Crosslinks EB coatings have high chemical and thermal resistance
ApplicationsCasting papersUnique tactile effectsUnique optical effects
HologramsReflective materialsLenticular
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Topside Embossing
ELECTRON BEAM
UNWINDCOATER
EMBOSSED FILM LOOP
REWIND
EMBOSSED PRODUCT
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Topside EmbossingEB advantages
No solvent or water to dryPattern defined by “parent” film (roll or loop)Cure through clear or opaque parent filmClean release from select parent film materialsParent film may be registered to printed webWide feature size (from microns to inches)Crosslinked EB coatings have excellent durability
ApplicationsDecorative packagingUnique tactile effectsUnique optical effects
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ConclusionsEB may be used in wide variety converting applicationsEB provides environmental and energy saving advantages compared to thermal curing processesThe nature of EB technology can enable unique converting processesThe development of smaller, lower cost equipment, makes EB an attractive technology for expanded use in converting applications