Cartridge Production Process – Laminating and Coating Hydrophobic Film

Process overview

  1. Parts Preparation
  2. Laminating and Coating Hydrophobic Film
  3. Cartridge Assembly
  4. Testing
  5. Packaging

2. Laminating and Coating Hydrophobic Film

ID2.1.
TitlePreparing PDMS adhesive
ScopePrepare PDMS as adhesive for dielectric film

Materials

  • DC 184, CH DE – Silicone Elastomer Kit, 1.1kg, Dow Corning
  • Mixing beaker
  • Micro-Balance

Step-by-step

  1. Add 10 gram of Part A (base) to beaker
  2. Add 1 gram of Part B (Curing agent) to beaker (ratio 1:10) (fig 1)
  3. Stir well using plastic spatula (fig 2)
  4. Put beaker into desiccator and put under vacuum for 2 minutes to degas (fig 3)

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ID2.2.
TitleStretching dielectric film
ScopePrepare dielectric film (ETFE) by stretching it flat

Materials

  • AGC Fluon ETFE Film, 12 um, with corona treatment
  • Masking tape

Step-by-step

  1. Carefully remove one layer of ETFE film from package and lay down flat (on glass surface) with corona treated side facing up (fig 1)
  2. Stretch film evenly by attaching it to surface using masking tape (fig 2)

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ID2.3.
TitlePriming Electrode boards
ScopeApply priming to masked electrode boards and protect with tape

Materials

  • Electrode board with makings applied
  • DOW CORNING® 1200 OS Primer
    (Primer for silicone elastomers, silicone foams and adhesives/sealants)

Step-by-step

  1. Measure 5 ml of primer into buffer container (always use buffer container to prevent contamination and product deactivation)
  2. Apply one coat of primer to electrode board using a lint free paper towel (fig 1)
  3. Allow allowed to air dry for 15 minutes
  4. Protect the surface by applying a masking tape over it (fig 2).
    Laminate electrode board soon after priming (< 6 hours)

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ID2.4.
TitleLaminating dielectric foil with PDMS
ScopeApply PDMS adhesive to electrode board and laminating ETFE foil
BuyShop link for Laminated and Coated Electrode Board

Materials

  • Electrode board with makings and priming
  • Mixed PDMS adhesive
  • Stretched ETFE foil

Step-by-step

  1. Remove protective masking tape from electrode board
  2. Apply a small amount of PDMS adhesive directly to the electrode array
  3. Spread the adhesive evenly using a squeegee.
  4. Remove all excess adhesive in a second pass with the squeegee. There should be as little adhesive on the surface as possible (just impregnated)
  5. Remove liners from top and bottom masking lines
  6. Apply electrode board to stretched ETFE film. Be careful when putting it down to not move and introduce wrinkles. Press down.
  7. Clean backside of electrode board from any excessive adhesive
  8. Cut out ETFE film around the electrode board to release it from the sheet.
  9. Wrap electrode baord with film applied to it into a folded piece of paper
  10. Pass the board wrapped in paper through a laminator
  11. Let the PDMS adhesive dry for 12 hours (covered with aluminum foil to prevent dust and charges)

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ID2.5.
TitleCoating film on electrode board
ScopeApplying a hydrophobic coating to the film on the electrode board
BuyShop link for Laminated and Coated Electrode Board

Materials

  • Electrode board with laminated film
  • Hydrophobic coating material (FluoroPel PFC1601V)

Step-by-step

  1. Put the electrode board on a spin-coater with vaccum chuck
  2. Apply 60 ul of FluoroPel onto the film on one edge of the board (fig 1)
  3. Spread the coating evenly over the whole surface of the electrode array using a plastic squeegee (fig 2)
  4. Spin at 2500 rpm for 30 seconds (fig 3)
  5. Cure on hot plate at 90°C for 20 minutes (fig 4)
  6. Store in board rack for further use

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