INTELLIVATION Large Area Roll to Roll Web Coating Systems

INTELLIVATION large area roll to roll web coating systems maximize efficiency, run to run consistency, and product quality in the high-end applications of today such as flexible optical coatings, thin film battery, security coatings, and medical device coatings, to name a few. The systems feature substrate pretreatment, up to six configurable process zones per coating drum, one to four temperature controlled coating drums, and a state of the art control system. Process zones can be configured for planar sputtering magnetrons, rotary sputter magnetrons, evaporation (thermal or e-beam) and plasma surface treatments like glow discharge and anode layer ion source. Designed for high throughput large area roll to roll thin film coating and roll to roll processing of flexible substrates including metal foils, polymer webs, textiles, flexible glass, and flexible ceramics, with coated widths up to 2,000mm. INTELLIVATION large area PVD web coating systems are proven in applications such as metallization, security films, optical coatings, flexible electronics, barrier films, medical devices, batteries and other leading edge roll to roll coating technologies. We invite you to come to our fully equipped R2R application development laboratory and try your product idea on our pilot & production scale R2R500 coater.

The powerful yet intuitive control system includes data logging and recipe based processing. A suite of optional in-situ metrology techniques provide for quality assurance of films and for rapid development cycles. The compact design of the R2R series maximizes efficiency by delivering high throughput in a small footprint.  Cost of ownership is further reduced through excellent ease of access for operation and maintenance and reduced utility costs as a result of a proprietary coating drum roller design.

1500mm web path roll stands

Large area roll to roll vacuum web coating system roll stands, shown with interleaving in place.

Large Area Vacuum Web Coating System Series Features:

  • Web Widths from 500 mm to 2,000 mm
  • Plastic & Metal Foils , Textiles, Flexible Glass
  • Industry Leading Compact Ergonomic Design
  • Versatile Web Paths
    • Web forward and backward enables multi-layer coating designs
    • Non-contact front surface web paths for defect free surfaces
    • Drum mode for coating straps or individual substrates
    • Interleaf removal and application
  • Single and Multi-Drum Web Coating Systems
  • Up to 6 Configurable Deposition Zones Per Drum
    • Evaporation (Thermal or E-beam)
    • AC or DC Planar Sputter Magnetrons
    • AC or DC Rotary Sputter Magnetrons
    • Plasma surface treatment

Thin Film Applications

  • Metallization
  • Flexible Circuits
  • Optical
  • Barrier
  • Decorative
  • Security
  • Magnetic
  • Thin film battery
  • High temperature Superconductors
  • Medical Devices
  • Tribological (Wear) Coatings

Substrates Processed

  • Polymers
  • Metal foils
  • Textiles
  • Nonwovens
  • Flexible glass

Industry Leading Low Ceiling Height

All systems can be installed with ceiling heights below 14’ (4.3m)

Provides flexibility for locating equipment in existing facilities

Industry Leading Facility Compact Footprint

With Industrial space at a premium for many companies the area occupied is remarkably small

  • 1m width    1,000 ft2    (93 m2)
  • 2m width     1,250 ft2    (116 m2)

Provides flexibility for locating equipment in existing facilities

Web Paths

Versatile Web Paths
  • Web movement forward and backward enables complex multi-layer thin film coatings
  • Non-contact front surface web path for defect free web handling
  • Interleaf removal and application for sensitive surfaces
  • Drum mode for coating straps or individual substrates
Web Control
  • Precise Tension Control
  • Enables coating of challenging substrates like flexible glass
Web speed and position monitoring
  • Permits precise alignment of coating positions on web
Web Control / Configuration
  • Web position recorded and monitored to sub millimeter precision
  • 5 zone tension control: payout, coating zone, take-up
  • Web paths are configurable with straight forward machine configuration changes.
    • All machines are pre provisioned for roller additions and alignment
    • Provides flexibility for developing new products and/or flexible manufacturing
  • HMI front panel changes with installed configuration making integration for the operator seamless
Planar Magnetron

Deposition Sources

Thin film sources:

R2R Series In-Situ Metrology

  • Optical Density
  • Sheet resistance / conductivity
  • Spectral reflectance
  • Spectral Transmission
  • Quartz Crystal Microbalance (thickness)
  • End-point Detection
  • Residual Gas Analyzer
  • Others

How can we help?

Interested in learning more about our large area web coating systems?

What are your web coating needs?