Spray Coater - 4D LABS User Facilities · Reinstall the syringe into the pump and confirm that the 3-way valve is pointing toward the system and the isolation valve is open. Reconnect

4D LABS, Simon Fraser University 8888 University Drive, Burnaby, B.C. V5A 1S6

E [email protected] 778.782.8084 F 778.782.3765 W www.4dlabs.ca

Spray Coater

Standard Operating Procedure

Revision: 2.0 — Last Updated: Jul.24/2014, Revised by Nathanael Sieb

Overview

This document will provide a detailed operation procedure of the SonoTek Spray Coater. Formal

Training is required for all users prior to using the system.

Revision History

# Revised by: Date Modification

1 Nathanael Sieb 2014-02-28 Initial Release

2 Nathanael Sieb 2014-07-24 Added solution restrictions.

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Document No. 4DSOP000X

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Table of Contents

General Information ................................................................................................................................. 3

Operation ................................................................................................................................................ 5

1. Startup ............................................................................................................................................ 5

2. Syringe loading ................................................................................................................................ 6

3. Sample loading ................................................................................................................................ 8

4. Path Programming ......................................................................................................................... 10

4.1 Program Set-up........................................................................................................................ 10

4.2 Adding Features ...................................................................................................................... 10

5. Sample Spray Coating .................................................................................................................... 13

5.1 Manual Mode .......................................................................................................................... 13

5.2 Automatic Mode ...................................................................................................................... 14

6. System Cleanup ............................................................................................................................. 15

References and Files ............................................................................................................................... 16

Contact Information ............................................................................................................................... 17

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General Information

The SonoTek ExactaCoat Spray Coater is an automated spray coating system. It has the following

features:

400mm x 400mm XY motion range

Integrated Contact Heating / Vacuum Plate (150 °C maximum)

Ultrasonic Accumist Nozzle, 120 kHz, 2mm - 6mm diameter spray area

SonicSyringe to keep particles in suspension within syringe

Simple to use operating and path design software

Multiple fluid lines to reduce cross-contamination risks

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There are two main software packages on the system. The Portal software controls the Spray

Coater hardware and the Pathmaster software is used to create the spray routines.

Within Portal there are three different sections. “Setup” is used to configure the operating pa-

rameters for the Auto routines. “Auto” is used to run programs that are already loaded into the machine

memory. Manual is used to test the system and configure operating parameters for routines run directly

from Pathmaster.

There are several hardware variables that can be adjusted to optimize the spray coating:

Flow rate

Shaping air

Path speed

Sonication power

All of these parameters are controlled through the Portal software.

The Accumist Nozzle allows for precise spraying with 120 kHz sonication. It is also easy to clean.

NOTE: Spray solutions are restricted to a maximum of 2% solids in an appropriate solvent.

All solutions must be approved by 4D LABS staff.

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Operation

1. Startup

Turn the main power switch on and wait for the lights on the teach pendant to turn off.

Start Portal and log in.

The instrument will check the exhaust and run through the initial system check. When prompted,

turn the door key, activate/deactivate the EMO, open/close the door, and home the system.

Click continue when reminded about Dip Switches.

Ensure that the proper fluid lines are connected such that your fluid will go as fol-

lows:

o Syringe 3-way valve Valve 1 or 2 Spray nozzle

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2. Syringe loading

In the Portal software, start Manual mode and open the Valves tab. Place a paper-towel or beaker

under the spray nozzle in the system.

Open the isolation valve your line is connected to. For the rest of this manual, we will as-

sume Valve 1 but you must choose the correct valve.

Point the 3-way valve to the system.

Withdraw the current fluid (should be clean methanol) from the lines into the syringe by pressing

the left arrow on the bottom of the syringe pump control panel.

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When the lines are empty and only air is being sucked into the syringe, stop withdrawing the sy-

ringe.

Unscrew the fluid line from the end of the syringe and attach a small tubing section to it.

Dispense the solution into a waste container.

Load the spray solution into the syringe by placing the tube in the solution and withdrawing the

syringe.

Remove the syringe from the pump and remove any air-bubbles from the syringe by positioning the

syringe upside-down and dispensing the air back into the stock solution.

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Reinstall the syringe into the pump and confirm that the 3-way valve is pointing toward the system

and the isolation valve is open. Reconnect the main line to the syringe.

The SonicSyringe can be activated by flipping the Trigger switch to Auto. The syringe sonication

will alternate 5 sec on/5 sec on. The power can be changed between Normal and Cavitate.

Dispense the solution using either the bottom-right arrow on the pump control panel or the pump

tab in the Portal software until the spray solution starts to come out the nozzle onto the paper-

towel.

Turn “Spray 1” from the valve tab on and confirm that the spray solution is atomizing. Adjust the

shaping air pressure as needed. The pressure needs to be high enough that the spray is atomizing,

but not so high as to get splash-back.

3. Sample loading

Place the substrate on the vacuum/hot plate. Use plastic transparency or aluminum foil

around the substrate to protect the stage from overspray of the solution.

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In the Portal software, start Manual Mode.

Go to the vacuum tab. Activate the vacuum zones as needed. Zone 1 is the center circle of holes

and zone 4 is the outermost circle of holes.

Turn on the hot plate if needed and set it to the desired temperature using the controller on the

system.

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4. Path Programming

4.1 Program Set-up

Open the Pathmaster software.

Select Open and Existing Project or Create a New Project.

Select the program you wish to modify or create.

To change the name of the program, go to Edit Program Name

4.2 Adding Features

There are numerous features available for programming. Some of these include:

Comments : add a note to the program

DMC Command : enter a direct tool command

o See example at the end of this section for how to program loops

Dwell : pause time

Area : defined by 3 points – start, direction, limit

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o Teach coordinates by entering manually or using the teach pendant

o Ensure correct valve is selected for the spray path needed

o Set the desired speed (50-80 mm/sec is a good range)

o Valve On and Off will actuate the valve a set time or distance after the start of the path or

before the end of the path

o Area Spacing determines the fill density

o Fast Area is best set as Arcs for smoother motion

2D path : defined by at least 2 points – follows path at same z-height as first position

3D path : defined by at least 2 points – follows path at varying z-height

Arc : defined by at least 3 points – start, point on curve, end of path

Circle : defined by at least 3 points in sequence along the desired circle

Dot : exposure at single point

FastPath : graphical representation of current spray paths (example below)

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Play Path or Run Selection: runs the currently selected path.

o Can be dry (no spray) or wet (with spray)

To change the parameters of the selected path, go to Modify Properties

To download the current project to the machine memory, go to Download Project

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5. Sample Spray Coating

5.1 Manual Mode

Start Manual mode and load the sample as described in section 3.

Set the Generator Power.

Set the Pump Speed.

Ensure that the correct valve is programmed in PathMaster and that the fluid path is

correctly set-up.

Open PathMaster and go to Run Selection or Run All.

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5.2 Automatic Mode

Go to Setup and set the Vacuum, Generator, and Pump the same way as described in

section 3 and 5.1. Set the system to Run Wet (with spray) or not (no spray).

Select the desired program to run.

Enter Auto Mode and press Cycle Start.

The system will automatically activate the vacuum, the SonicSyringe, and run the program.

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6. System Cleanup

In the Portal software, start Manual mode and open the Valves tab. Place a beaker under the

spray nozzle in the system.

Open the isolation valve the line is connected to.

Point the 3-way valve to the system.

Withdraw the spray solution from the lines into the syringe by pressing the left arrow on the bot-

tom of the syringe pump control panel.

When the lines are empty and only air is being sucked into the syringe, stop withdrawing the sy-

ringe.

Unscrew the fluid line from the end of the syringe and attach a small tubing section to it.

Dispense the solution into a container.

Use a rinse solution such as methanol to clean the syringe.

When the syringe is clean, reinstall the syringe into the pump and reconnect the main fluid line to

the syringe.

Point the 3-way valve to refill.

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Withdraw the methanol into the syringe.

Point the 3-way valve to system.

Use the right-arrow on the syringe pump or activate Spray 1 in the valves tab and run the spray in-

to the beaker until the tubing and nozzle are clear and filled with clean methanol. It will be easi-

est to use a high flow rate (>2 mL/min). The syringe will need to be refilled 2-3 times.

If further cleaning of the nozzle and syringe is necessary, contact the 4D LABS staff.

Dispose of the waste in an appropriate waste container.

7. Shutdown

Close PathMaster if it is open.

Press Stop on the Portal software.

Quit the Portal software.

References and Files

SonoTek Spray Coater Manual and training notes.

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Contact Information

Questions or comments in regard to this document should be directed towards Nathanael Sieb

([email protected]) in 4D LABS at Simon Fraser University, Burnaby, BC, Canada.

Documents

Spray Coater - 4D LABS User Facilities · Reinstall the syringe into the pump and confirm that the 3-way valve is pointing toward the system and the isolation valve is open. Reconnect