Our Work

National Coating Corporation has worked in many industries and produced a wide variety of products and value-added services.

Industries

  • Agriculture
  • Alternate Energy
  • Automotive
  • Aerospace
  • Bio-Medical
  • Construction
  • Consumer Products
  • Cryogenic
  • Defense
  • Industrial
  • Mining

Thick times two, with material issues.

A thick adhesive coating on a thick paper substrate. The paper often has faults, but the end product absolutely cannot. The adhesive has four components which dry at different temperatures.

Specification

  • Apply 0.002” – 0.005” dry film thickness of solvent-based adhesive onto 0.050” caliper high value specialty paper. Adhesive coating must be dry enough to roll up without blocking and cannot contain bubbles or other defects. Slit to specified widths.

Challenges

  • Paper has multiple machine direction waves/ridges up to 0.125” high from prior processing.
  • Adhesive has four distinct solvents with different evaporation rates and boiling temperatures.

Solutions

  • Design and build vacuum table to flatten material under coating head. Design system to balance minimum suction required to flatten versus maximum vacuum that will add excess tension to the material and/or draw adhesive into the paper.
  • Work with adhesive supplier to provide optimal viscosity so that coating doesn’t run from “hills” to “valleys” while still wet.
  • Utilize 4 zone – 120 ft oven. Set the temperatures in each zone to correspond to each different solvent. This provides for the sequential evaporation of each solvent and eliminates surface skinning which may result in bubbles and poor surface adhesion.

Results

  • After appropriate testing and validation, NCC has been the single source supplier to this customer for over a decade.
After implementing its solutions, NCC is able to demonstrate a process that is in control and yields long-term capability of 1.85 Cp and 1.78 Cpk

Film Thickness

Woven Carbon – conductive, pliable and weave faults

Coating woven carbon is complicated – it comes with weave faults, it tends to stretch and it’s highly conductive.

Specification

  • Saturate woven carbon material with phenolic resin and direct ship defect-free material to their customer at specified slit widths.

Challenges

  • All material shipped to customer must be defect-free and certified to be within specifications.
  • Material is extremely susceptible to distortion from tension.
  • Material as received has low frequency of random weave “defects”; yarn knots, slubs, missing threads and holes, which cannot be shipped.
  • Loose carbon dust/fibers/threads are excellent conductors and may short-out equipment.

Solutions

  • Install Beta Gauge backscatter radiation measurement system to measure material before and after saturation to determine resin content of each final slit.
  • Install in-line marking system to permanently identify all material that falls outside specification range.
  • Design and install a carrier belt within the oven that maintains a “minimum controllable tension” to prevent material distortion.
  • Install dust containment and collection system and create positive pressure in appropriate electrical systems.
  • Design and install inspection system for 100% inspection and identification of weave defects.
  • Develop protocol to remove/mark defects in the material.
  • Work with customer to use special tape that is visible to customer’s machine optics when making splices and/or marking defects in the material.

Results

  • After appropriate testing and validation, NCC has been the single source supplier to this customer for almost two decades.
After implementing its solutions, NCC is able to demonstrate a process that is on control and yields long-term capability of 2.11 Cp and 2.04 Cpk.

Carbon Fabric Material | Resin Content

Product needs development, as well as raw materials

Our client knew the function they needed, but the product was not fully developed and neither was the raw material.

Specification

  • Saturate wet-laid aramid with phenolic resin and apply carbon particles to the surface. Sand surface after processing to hold tight tolerance. Slit to specified widths.

Challenges

  • Specifications for raw materials not fully developed.
  • Specifications for final product not fully developed.
  • How to evenly and randomly distribute particles onto the surface.
  • How to hold tight thickness tolerance.

Solutions

  • Close collaboration with customer to fully understand material performance requirements, key material and process parameters.
  • Provide multiple production ready development samples for evaluation and analysis.
  • Jointly determine optimal product and process specifications.
  • Work with raw material supplier to develop material and process specifications based on saturation process and final product requirements.
  • Design and implement proprietary granule distribution system.
  • Provide boundary condition samples to customer for final product approval.
  • Work with specialty equipment manufacturer to implement roll-to-roll precision sander.

Results

  • After appropriate testing and validation, NCC has been the single source supplier to this customer for over a decade.
The process of applying granules to the surface of the aramid has a 3.05 Cp and 2.98 Cpk when compared to product specifications.

Applied Granule Wt

After a complex process, the complete product weight has a 2.10 Cp and 1.95 Cpk.

Complete Wt

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Our Office

National Coating Corporation

105 Industrial Way
P.O. Box 406
Rockland, MA 02370