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Drying of Thin Films of Polymer Solutions Coated over Impermeable Substrates

机译：涂覆在不渗透基材上的聚合物溶液薄膜的干燥

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摘要

The manufacturing of adhesive tapes, photographic films, magnetic media, and many other products involves the coating and drying of thin films of polymeric solutions or emulsions over an impermeable substrate. Wet thickness may vary from 1 micron to 500 microns and solid content from 3% to 50% or more. The drying process generally occurs in convective ovens, where air temperature, airflow rate, and solvent partial pressure may be adjusted. In many cases, it is the manufacturing step that controls the productivity; therefore, it is very important to optimize the oven conditions to minimize the oven residence time without causing defects on the coated film and keeping the residual solvent inside the final product within specification limits. A drying model and a simulation software based on it were developed in order to solve the transient mass and heat transfer equations that describe the drying of a polymer solution containing two different solvents. The resulting system of equations shows strong non-linearity due to the free surface and the dependence of diffusion coefficients on solvent concentration and film temperature. The integration in time was performed with a fully implicit method, and at each time step, Newton's method was used to solve the resulting non-linear system of algebraic equations. An example of using the drying simulator to optimize an industrial adhesive tape line is discussed. The gain in productivity achieved by the analysis was greater than 40%.
机译：胶带，摄影胶片，磁性介质和许多其他产品的制造涉及在不渗透的基材上涂覆和干燥聚合物溶液或乳液的薄膜。湿厚度可在1微米至500微米之间变化，固体含量可在3％至50％或更高的范围内变化。干燥过程通常发生在对流烘箱中，在此处可以调节空气温度，气流速率和溶剂分压。在许多情况下，控制生产率的是制造步骤。因此，优化烘箱条件以最小化烘箱停留时间而不引起涂膜缺陷并将最终产品内的残留溶剂保持在规格范围内非常重要。为了解决描述包含两种不同溶剂的聚合物溶液干燥的瞬态质量和传热方程，开发了干燥模型和基于该模型的模拟软件。由于自由表面以及扩散系数对溶剂浓度和膜温度的依赖性，所得方程组显示出很强的非线性。使用完全隐式方法进行时间积分，并且在每个时间步均使用牛顿法来求解所得的非线性代数方程组。讨论了使用干燥模拟器优化工业胶带生产线的示例。通过分析获得的生产率提高超过40％。

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