Latest Development in Vacuum Metallisation

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1 Latest Development in Vacuum Metallisation Professor Nadir Ahmed Vacuum Metallising Consultant General Vacuum Equipment Ltd. Pennine Business Park, Pilsworth Road, Heywood OL10 2TL England Tel: +44(0) Mobile: +44(0)

2 What is Vacuum Metallisation? > Deposition of a coating inside vacuum chamber > Clean Process Excellent control of coating thickness Excellent control of optical and physical properties > Cost Effective Can be done at fast line speed > Film outgassing to remove moisture/solvent retention > Durable coating Longer lifetime > Environmently friendly process > Dry coating Effluent free

3 Vacuum Metallising Process Unwind Rewind Plasma Treatment mbar Cooled Drum Optical Monitor Winding Zone Coating Zone mbar Evaporation Source

4 Advances in Vacuum Metallisation Web Speed,m/s Web Width,m Film Gauge(PET) 48(12µ) 36(9 µ) 24(6µ) 20(µ) Film Gauge(OPP) 70(17.5µ) 60(15µ) 48(12µ) 36(9µ) Optical Density 1.5 < Al Evaporation rate,g/min In-Line monitor system No Optical Optical & Conductivity Optical & Conductivity Feedback Control No Rare 80% 100% Uniformity > 10% ±10% ±5% <±5%

5 Development in Vacuum Metallisers > Vacuum Technology > Fast, Efficient Pumping system Vacuum Monitoring System Vacuum Control System > Winding Mechanism Efficient to handle various film thicknesses Good tension Control > Evaporation Source > Good, reliable design Ability to evaporate different materials > Process Control > Fast and Efficient Feedback system Easy to operate

6 Vacuum Metallisation for Holographic products > Can be integrated within holographic image > Top layer Intermediate etched layer De-metallised > Add lustre & visual appeal Silver, gold, copper, chrome or other colours > Add new functional properties > Durable coating Environment, scratch resistance, etc > Can be designed to fit application > High reflectance: Al & other metallic coatings Semi-transparent: Zinc Sulphide, Titanium Oxide, etc

7 The K Series Metalliser

8 Vacuum Metallising for Holographic Products Top Coat Base Coat Metal or Dielectric Coating Substrate Embossed Image

9 Others 5% Zinc Sulphide 30% Titanium Oxide 5% Aluminium 60% Existing Market For Metallised Holographic Products

10 Examples of Vacuum Metallised HRI Coatings HRI Material Deposition Method Refractive Index Reflectance Relative Coating Properties Relative Line Speed Relative Material Cost TiO 2 -Electron Beam -Sputtering (Reactive) % Hard Slow Medium ZrO 2 -Electron Beam -Sputtering (Reactive) % Hard Slow High ZnS -Thermal Evaporation > % Soft Fast Low

11 The Holosec The Answer to Holographic Metallisation

12 The Holosec Metalliser

13 The Holosec: Advances in Vacuum Metallisation

14 The Holosec: Schematic of Vacuum Pumps & Evaporation Source

15 The Holosec Metalliser

16 The Holosec

17 TECHNICAL PERFORMANCE DATA Maximum web width Maximum effective coating width Minimum effective coating width Maximum roll diameter Unwind core76 mm (3 ) Film type 400 mm 380mm 150mm 450mm 76mm(3 ) Polyester Film thickness µ Line speed Winding tension 10m/min to 200m/min Newtons

18 The Holosec Zinc Sulphide (HRI) Chrome (Cr) Aluminium (Al) Silicon Oxide Copper (Cu) Silver In Line registering Pattern de Metallising

19 Plasma Pretreatment 5kW, 40kHz AC power supply. Magnetically enhanced, water-cooled electrode assemblies. Retractable for ease of thread- up. Plasma Treatment equipment specification. One Mass Flow Controller complete with shut off valve. Upstream control system of MFC via computer system

20 Surface Energy (Dyne/cm) Plasma Treatment: Improving Adhesion Enhancing Surface Energy Untreated 30 m/min 200 m/min 0 Substrate: 12 µm base lacquered PET Plasma conditions: 40 khz, 5 kw [Ar/O2]

21 Applications Of The Holosec

22 Pattern De-Metallising

23 Examples of Vacuum Metallisation for Holographic Products Aluminium on credit cards Copper and metallic ink on Banknotes Zinc Sulphide (HRI) on Security Documents Chromium for Outdoor Holograms

24 Copper Coating

25 Conclusions 1. Vacuum metallising is an integral part of Holograms. 2. New coatings can add Smart features to holographic products 3. The Holosec metalliser is designed for Holographic Products 4. The Holosec is a compact and cost effective vacuum metalliser 5. The Holosec can meet present and future requirements for unique coatings

26 THANK YOU