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Process Development...

Three Success Stories

A NEW PRODUCT; One of our clients experienced a 47 percent reject rate after coating on a new product. First identified as a contamination issue the company worked vigorously to improve the quality without any success. DOE’s performed by UV Research indicated that the problem was created upstream by raised styrene fibers lifted from the molded surface, by the solvent used in the coating, during the coating process. A resin formulation reduction of 2% of styrene in a molding compound reduced the product reject rate after coating by 97 percent.

AN EXISTING PRODUCT; Another example can be found in an application of a slip coating on a rubber door seal. As the slip coating was applied and cured, peeling of the coating was experienced on some of the seals. DOE’s performed by UV Research identified the problem as a surface property defect on the rubber surface. Further research showed that although the rubber was corona treated prior to coating the surface areas experiencing peeling had a surface tension less than required. Additional material research with the co-operation of the rubber supplier solved the problem.

A COMPLEX PROBLEM; A case particularly related to UV coating can be found in the manufacturing of vinyl signs. In this third example, yellowing of the scratch resistant topcoat was experienced shortly after production. UV Research was ask to solve the problem. DOE’s performed by UV Research showed that the issues were both process and formulation related. As mentioned in the introduction, the interaction of the optical and physical characteristics of the lamp system, and the physical properties of the coating are an integral part of the coating performance. Scratch and Stain resistance are a function of wavelength. Flexibility is a function of irradiance. Tests showed that a through-cure could be achieved at a lower irradiance without loss of adhesion to the substrate. As a result a slight reduction in photoinitiator content within the formulation solved the problem.

Integrating Engineering

Since product and process design have such a major influence on the competitiveness of the company, it is critical that product design functions are better integrated with other functions of the company. This means integration of all engineering functions among themselves - product design, process design, electrical, mechanical, and software design. Then integration expands to include the rest of the company and external organizations such as customers and suppliers.