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Ossila Slot-Die Coater

User Manual

Ossila.com

8

Ossila Limited © 2019

Figure 2.2

Slot-die coater gantry schematic.

Figure 2.3

Slot-die coater syringe pump schematic

1

Digital Height Gauge

2

Manual Micrometer

3

Safety Clip

4

Slot-Die Head

5

Luer Lock Adapter

6

Gauge Roller

7

Heated Stage

8

Thumb Screw

14  Plunger Pusher
15  Plunger Clip
16  Flange Clip
17  Syringe Holder
18  Barrel Clamp

9

Motor

10  Coupling
11  Lead Screw
12  Wing Nut
13  Rail Guide

5

4

6

7

8

2

1

3

9

10

11

12

14

15

16 17

18

13

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Summary of Contents for Slot-Die Coater

Page 1: ...enabling materials science Ossila com Slot Die Coater User Manual Manual Version 1 0 J Product code L2005 Product Version 1 0 Software Version 1 0 ...

Page 2: ... Emergency Stop 13 6 5 Tube Clip 13 6 6 Operational Safety 14 6 6 1 Pinch Points 14 6 6 2 Hot Plate 14 6 6 3 Sources of Ignition 14 6 6 4 Fire Hazard 14 7 Maintenance 14 7 1 Cleaning 14 7 2 Repair Service 15 8 Installation 15 9 Operating the Slot Die Coater 17 9 1 Slot Die Coater User Interface 17 9 2 Program Operation 18 9 2 1 Turning the unit on 18 9 2 2 Settings Mode 19 9 2 3 Manual Mode 21 9 2...

Page 3: ... Limited 2019 9 2 10 Running a Program 32 10 The Coating Process 34 10 1 Gap Height 34 10 2 Worked Example 35 11 Slot Die Coater Troubleshooting 37 12 Appendix 38 12 1 Minimum and Maximum Flow Rates 38 13 List of Related Products 39 14 Revision History 41 ...

Page 4: ...ng product Product L2005A1 Slot Die Coater Serial number L2005A 1000 1000 1000 xxxx Object of declaration L2005A1 Slot Die coater The object of declaration described above is in conformity with the relevant Union harmonisation legislation Machinery Directive 2006 42 EC EMC Directive 2014 30 EU RoHS Directive 2011 65 EU The following harmonised standards and technical specifications have been appli...

Page 5: ...emo na vlastitu odgovornost da je navedena oprema sukladna s mjerodavnim zakonodavstvom EU a o usklađivanju koje je navedeno na prethodnoj nim stranici ama ovoga dokumenta Italiano Dichiarazione di conformità UE Produttore Ossila Ltd Solpro Business Park Windsor Street S4 7WD UK Si dichiara sotto la propria personale responsabilità che l apparecchiatura in elenco è conforme alla normativa di armon...

Page 6: ...dena oprema skladna z veljavno uskladitveno zakonodajo EU navedeno na prejšnji strani prejšnjih straneh tega dokumenta Suomi EU vaatimustenmukaisuusvakuutus Valmistaja Ossila Ltd Solpro Business Park Windsor Street S4 7WD UK Vakuutamme täten olevamme yksin vastuussa siitä että tässä asiakirjassa luetellut laitteet ovat tämän asiakirjan sivuilla edellisillä sivuilla kuvattujen olennaisten yhdenmuka...

Page 7: ...ay from techniques that are incompatible with large scale processing such as spin coating The Ossila Slot Die Coating System has been designed for simple operation easy maintenance and affordability An integrated high precision Syringe Pump allows for accurate and reproducible flow rates which are essential for controlling thin film thicknesses The substrate stage is levelled using a simple three ...

Page 8: ...inge pump schematic 1 Digital Height Gauge 2 Manual Micrometer 3 Safety Clip 4 Slot Die Head 5 Luer Lock Adapter 6 Gauge Roller 7 Heated Stage 8 Thumb Screw 14 Plunger Pusher 15 Plunger Clip 16 Flange Clip 17 Syringe Holder 18 Barrel Clamp 9 Motor 10 Coupling 11 Lead Screw 12 Wing Nut 13 Rail Guide 5 4 6 7 8 2 1 3 9 10 11 12 14 15 16 17 18 13 ...

Page 9: ...te Thickness 13 mm Stage Surface Flatness 20 μm Stage Surface Roughness RMS 3 μm Stage Levelness 50 μm Power Supply Input 90 264 VAC 50 60Hz Output 24 VDC 6 25 A Dimensions Depth x Width x Height 360 mm x 280 mm x 190 mm Weight 10 kg Table 3 1 Slot Die Coater specifications Values determined at a stage temperature of 21 C Slot Die Coater Specifications Slot Die Head Material Stainless Steel Slot D...

Page 10: ...ng parts that might wear out over time Damage from external sources such as weather electrical outages or power surges Equipment that has been modified or serviced by anyone other than an Ossila engineer Equipment that has been subjected to chemical damage through improper use Equipment that has been operated outside the usage parameters stated in the User Manual associated with the equipment Equi...

Page 11: ...d for the country of purchase This is in accordance with European Commission regulations and British Standards Use of any other electrical power cables adapters or transformers is not recommended Warning Only use the 24V power adapter and power cord supplied with the unit If using flammable or hazardous solvents users are expected to be trained in their usage and carry out a risk assessment Keep t...

Page 12: ...ng or servicing this equipment can result in serious injury Pay attention to the following hazards when operating this equipment Pinch point and entanglement hazards are present during operation of the syringe pump and stage As a precaution users should avoid handling or leaning over the equipment during operation to avoid possible crushing or entanglement of hair and or clothing The unit weighs a...

Page 13: ...n using the on off switch at the back of the unit The emergency stop button should not be used for powering down the system after use and should only be used in emergency situations Figure 6 1 The emergency stop button mounted to the front of the slot die coater 6 5 Tube Clip A tube clip has been provided with the system The clip chain attaches to the slot die head using a simple washer The clip i...

Page 14: ...on risk assessments should consider potential fire hazards that can occur when heating solvents to high temperatures Many common solvents used within laboratories have a flash point below 120 C leading to the risk of ignition Adjust experimental parameters to reduce risk of solvent combustion 6 6 3 Sources of Ignition Solvents can often be heated beyond their flash point where any source of igniti...

Page 15: ...e from vibrations temperature extremes and highly flammable or explosive materials Keep the area surrounding the machine clear with approximately 1 m clearance above the machine and around 30 cm clearance on the sides 2 Remove the cable ties that secure the gantry during shipping 3 Before plugging in the Slot Die Coater ensure the power switch on the unit is switched to the 0 position off 4 Connec...

Page 16: ...ser Manual Ossila com 16 Ossila Limited 2019 Figure 8 1 Installation of the Slot Die Coater by plugging in the power supply cable Figure 8 2 Each digital height gauge should be fitted with one LR44 battery by removing the cap ...

Page 17: ...iver and the slot die stage can be moved Program Enter Program Mode where saved programs can be selected and or edited Settings Enter Settings Mode where syringe properties can be defined and hotplate temperature offsets can be added Up Navigating Up through menus increasing selected values by 1 increasing unit size Down Navigating Down through menus decreasing selected values by 1 decreasing unit...

Page 18: ...oater power switch ON position 1 The bootup screen will show 2 After the bootup reset the stage to its home position by pressing This will move the stage to the furthest back point 3 Whilst the stage is moving to the home position the following message will be shown 4 Once the system is at the home position the Program Mode page will be prompted ...

Page 19: ...navigate to the Hotplate line and press to switch ON the hotplate The Heater LED will blink ON OFF whilst the hotplate is heating and remain ON when it reaches the set temperature You can switch OFF the hotplate by pressing again Note The Hotplate icon on the screen will blink RED while the hotplate is switched ON 3 The hotplate temperature is set by navigating to the Hotplate temp line and pressi...

Page 20: ...rface temperature not supplied Note The displayed temperature has the offset applied and therefore will appear higher than the set point temperature when a positive offset is applied 5 To change the syringe size navigate to the Syringe size line and press to enter edit mode To change to different sizes of the syringe press or to scroll between the pre set sizes Press again to exit the edit mode No...

Page 21: ...l Mode Manual Mode allows direct control over the syringe pump and stage positions Entering edit mode on any parameter will turn the text of the parameter red WARNING Pinch points and entanglement The rotation of the lead screw coupling and the movement of the plunger pusher present entanglement and pinch hazards Care should be taken when the system is running 1 To enter Manual Mode press located ...

Page 22: ... will be updated automatically 4 Press to select the Syringe 5 The manual dispense rate of the syringe is calculated based on the selected syringe size in Settings Mode Press to cycle through preprogramed values 6 To dispense the solution manually press or to move the syringe plunger position The volume of solution dispensed will be automatically calculated and displayed ...

Page 23: ... in each The current program can be changed by navigating to Program with the button Press to enter edit mode and press or to change the program number Press to exit edit mode Program number can also be changed using or without entering edit mode 2 To change the number of steps in the program navigate to steps line and press to edit the value Press or to change the value Press to exit edit mode 3 ...

Page 24: ...ach step To edit the coating length navigate to the Coating length line and press to edit The digit cursor will appear under the number Note If the coating length is set above the maximum length allowed 100 mm a warning will appear to notify the user The system will automatically calculate the remaining allowed length and set it in the current step 6 To change the Coating Speed for the current ste...

Page 25: ...allowed rate value for the selected syringe size To see the minimum and maximum rates for each syringe refer to Section 12 1 9 To include the delay in the current step navigate to the Stage delay and press to enter edit mode The digit cursor will appear under the number Users can navigate between the digits by pressing and buttons To change the value of the selected digit press and buttons Press a...

Page 26: ...re may be defects within the coating The head should be disassembled and cleaned after each use 2 Select a shim with appropriate width for the substrate you wish to coat Add the required number of shims to get the gap thickness required Each shim is 100 μm thick 3 Clamp the shims between the two halves of the slot die head and using the four shorter corner screws to clamp the slot die head togethe...

Page 27: ...et Using the two longer bolt on screws attach the slot die head to the slot die system via the two gantry threaded holes The side of the head with the socket for the Luer lock adapter should face outwards 6 Place the Luer Lock adapter through the washer at the end of the safety clip Attach the stainless steel Luer lock adapter to the slot die head When not attached to the tubing the safety clip ch...

Page 28: ...rature before levelling the stage 1 Zero height gauges relative to the head In Manual Mode use the button move the stage so that the gauge rollers are no longer touching the top surface Turn the digital height gauges on by pressing OFF ON and set them to zero by pressing Zero 2 Level the stage across the width Using the button move the stage so that the gauge rollers are on the top surface of the ...

Page 29: ...ready be at or close to the stage home position To ensure this is the case return the stage to the stage home position by pressing the button To increase the accuracy of the levelling repeat steps 2 and 3 9 2 7 Installing the Syringe 1 There are two sets of holes on the plunger pusher to accommodate different sized syringes The height of the plunger clip can be adjusted by changing which set of ho...

Page 30: ...ving sufficient space between the flange clip and the plunger clip to attach the syringe Loosen the screws on the flange clip and the plunger clip as much as possible and insert syringe The plunger clip can be moved vertically to better fit the syringe 5 Replace the barrel clamp and secure with the wingnut then tighten the wingnut screws on the flange clip and the plunger clip until the syringe is...

Page 31: ...te operation instructions There is a slight expansion of the stage when heated which may affect the alignment and the readings on the digital height gauges WARNING Hot Surface The hotplate is hot when heated and contact with skin can cause burns Care should be taken when the system is running 1 Zero the digital height gauges to the top of the substrate First place the substrate on the stage with t...

Page 32: ...olution should be formed across the width of the substrate by dispensing a small amount of solution in the Manual Mode The slowest dispense rate should be used to avoid dispensing too much solution onto the substrate which can cause defects Solution should be pumped until a small amount comes out of the head and forms a meniscus on the substrate surface Alternatively a program step can be used to ...

Page 33: ...apsed time until delay time is up Note If the coating speed has not been set for all off the program steps a warning will appear to notify the user Running will be aborted until the speed is set 2 You can start coating at any stage position by positioning the stage in Manual Mode However the position is tracked so that it will not exceed the maximum travel distance of 100 mm Where the total coatin...

Page 34: ...troubleshooting To know the minimum gap height for coating a stable film you must first know what wet film thickness you are wanting to coat If you are working from a dry film you must begin by calculating the percentage volume of solids in solution This can be done if the mass of the liquid the mass of the solid the density of the liquid and the density of the solid are all known Volume Solids ma...

Page 35: ...llowing the instructions in Section 9 2 6 to a levelness of 50 µm i e the maximum absolute value seen on either digital height gauge was 50 µm across the length of the stage iv A solution of dye in TCE 20 mg mL was prepared and filtered using a 0 45 µm PVDF hydrophobic syringe filter to ensure that no contaminants were present that can cause defects in the final film A 5 mL syringe was filled with...

Page 36: ... 9 2 4 and the program run vii The coated film is shown and achieved a film thickness of 80 nm Note that edge defects at the start and end of coating can be minimised by use of sacrificial substrates before and after the main substrate wishing to be coated viii The film shown above used a stage speed of 14 mm s with a 4 µL s flow rate ...

Page 37: ...la for a replacement power supply adapter No obvious cause If all the above causes have been considered there may be a fault on the control board Please contact Ossila for information Motor Stalled Syringe Pump Syringe has hit first safety switch There is not enough solution in the syringe and the moving part of the pump has hit the safety switch Load more solution into the syringe so the plunger ...

Page 38: ...ie coating theory Slot Die Coating Guide to Troubleshooting Defects https www ossila com pages slot die coating defect troubleshooting 12 Appendix 12 1 Minimum and Maximum Flow Rates Table 12 1 Minimum and maximum flow rates possible with different sized syringes Syringe Volume Syringe Diameter Minimum Flow Rate Maximum Flow Rate 1 mL 4 69 mm 0 021 µL s 86 4 µL s 2 mL 9 65 mm 0 087 µL s 365 7 µL s...

Page 39: ...terdigitated ITO Substrates for OFET and Sensing ITO Coated Scale Up Substrates S281 A 25 X 75 mm unpatterned ITO glass substrate useful for custom patterning and other varied uses Quartz Coated Scale Up Substrates S261 These ultra flat glass substrates have thin 20 nm layer of synthetic quartz on the surface and are useful for control tests coating experiments and a variety of other uses Related ...

Page 40: ...nge of coating widths altering internal pressure and allowing customisation for different solution viscosities Available with widths of 25 mm or 50 mm PTFE Tubing L2005A1 E3 Ossila s PTFE tubing is pre assembled with the necessary Luer lock connections for easy use with the slot die coater Having separate tubing for each different material reduces the chance of cross contamination and improves the...

Page 41: ...to substrate distance changed to 13mm 1 0 E 21 08 2018 Removed Warranty Information 1 0 F 18 08 2018 Edited formatting 1 0 G 22 10 2018 Thorough copyedit for SPG and formatting 1 0 G 24 10 2018 Updated corrected DoC and altered servicing section 3 6 and 3 8 1 0 I 10 05 2019 Reformatted instructions for clarity 1 0 J 22 05 2019 Changes to the diagrams to reflect the latest builds and software and f...

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