Expert Details

Expert in Polymer Design and Synthesis, Coating Formulation, Defect Analysis, Process Improvement

Expert ID: 726178 Minnesota, USA

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Expert in Formulating, Applying, Curing, and Troubleshooting Coatings for Ophthalmic Lenses, as well as Other Transparent or Polymeric Articles

Chemistry
With over 25 years of industrial experience, Expert, a degreed chemist, is an authority on the materials, equipment, and processing aspects of coating ophthalmic lenses, as well as other substrates.
Expert has a Bachelor of Science degree in chemistry with more than thirty years of experience designing, synthesizing, compounding, testing, manufacturing, molding, laminating, and using novel polymers for various coating, ink, adhesive, as well as other applications in a wide variety of industries. He is well experienced with acrylics, alkyds, aminos, epoxies, phenolics, polyesters, polyolefins, urethanes, and siloxanes using various application methods on an array of substrates utilizing diverse curing techniques. My experience includes waterborne, high solids, lacquer dry, oxidative cure, thermal cure, radiation cure, multiple component, and other systems.

His expertise also includes the areas of defect analysis, process improvement, technical writing, plus assorted analytical methodologies, including FTIR, GC, NMR, HPLC, and optical microscopy. In addition, He is knowledgeable in the area of regulatory affairs. He is well established as an innovative, motivated, organized, proactive, productive, and professional, scientist having excellent work habits with a proven track record who is committed to meeting challenging deadlines. His publications include ten US patents and two technical articles.

Coatings
Expert is extremely knowledgeable in the chemistry of formulation, surface preparation, application, and cure of coatings, especially, but not exclusively, those coatings that are used on ophthalmic lenses.

Practical Manufacturing Experience
He has personally been involved in the establishment of commercial cleaning, coating, and curing processes at various locations worldwide. He is very knowledgeable of the materials, equipment, and processes that are or can be used in coating all types of ophthalmic lenses, including all lens geometries, whether cast or injection molded.

Ophthalmic Lens Coatings, Siloxane Coatings, Waterborne Coatings
With regard to coatings, Expert has invented and successfully used in various manufacturing facilities, a wide variety of coatings, a number of which have been patented, proving that he is both practical as well as sound in theory. Examples include coatings for adhesion promotion, scratch resistance, dye absorption, photochromic activity, temporary protection, and other special purposes. These coatings range from the organometallic siloxane variety to the purely organic types such as acrylics and polyesters. His expertise includes waterborne, solventborne, and solvent free systems.

Polymer Formulation, Polymer Synthesis, Coating Formulation
Expert has formulated as well as synthesized various types of polymers for a wide variety coatings, inks, and adhesives. These polymers include addition polymers such as acrylics as well as condensation polymers such as alkyds, polyesters, and polyurethanes. He has also formulated commercially successful products from those polymers. In addition to coatings, he has also formulated other commercially successful products, including cleaning solutions, inks, and surreptitious marking materials for use in such things as security features, or to assist in inventory control, among other purposes.

Curing Techniques
Expert has extensive expertise with coatings that are cured using heat as well as coatings that are cured with various forms of radiation, whether ultraviolet light, visible light, or radiant heat, including both acrylate and oxirane functional systems.

Cleaning, Surface Preparation, Coating Application
With regard to application equipment and processes, his knowledge encompasses dip as well as spin application methods. Furthermore, he has designed processes for cleaning, surface preparation, and drying substrates prior to the subsequent application of a coating, often in a clean room environment.

Analytical Chemistry, Defect Analysis, Trouble Shooting,
Expert possesses great troubleshooting skills, having done defect analysis and process improvement for many years. He has extensively used FTIR as well as FTIR microscopy in conjunction with a variety of IR sampling techniques for the purposes of analyzing coating defects, quality control, kinetic studies, and comparing competitive materials that were obtained by legitimate means. He is experienced with optical microscopy, UV-Vis, GC, and other instrumentation that is commonly used for analysis or other types.

With the use of carefully designed experimentation, a complete reformulation was conducted of a radiation curable coating that was intended for use on ophthalmic lenses and other optical devices. The new coating product provides superior mar resisatnce, adhesion, durability, solution stability, and cost, as compared to all other radiation curable coatings that are presently used in this industry. This has been confirmed by an independent testing laboratory.FTIR microscopy was used to identify the chemical composition of numerous microscopic particle defects that were ocurring in a precision coating operation. FTIR was then used to scan the suspected source of the particles. This gave an exact match, providing proof positive as to the source of the contaminant, and led directly to the elimination of a longstanding, expensive problem such that the yield was dramatically increased.Used optical microscopy to quickly but correctly determine the root cause of a sporadically recurring defect in a laminated film product that had plagued the client for several years in spite of their best efforts and the best efforts of others to resolve the issue.Determined the cause of instability in a coating formulation that was resulting in various coating defects, reduced shelf life, and, ultimately, premature gelation. Proposed practical modifications to both the formula and the process that was used to prepare the organometallic coating solution. The combination of modifications completely and permanently eliminated the problem.One particular client was in jeopardy of losing a $17MM acount due to the inability of their customer to use expert's client's product in a manufacturing process. It appeared that the customer's manufacturing process was resulting in damage to the coating that was on the product that was being purchased from his client. A tactful meeting with his client along with their customer at the customer's facility allowed for the determination of the defect and the cause. This was confirmed via relatively simple testing and was corrected, resulting in the retention of the business. A letter of appreciation from the client is on file.

Expert may consult nationally and internationally, and is also local to the following cities: Minneapolis, Minnesota - Saint Paul, Minnesota - Rochester, Minnesota - Burnsville, Minnesota - Saint Cloud, Minnesota - Eden Prairie, Minnesota - Minnetonka, Minnesota - Eau Claire, Wisconsin

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Education

Year Degree Subject Institution
Year: 1983 Degree: BS Subject: Chemistry Institution: University of Minnesota

Work History

Years Employer Title Department Responsibilities
Years: 2005 to Present Employer: Undisclosed Title: President and CEO Department: Corporate Responsibilities: As President and CEO of the corporation, he is ultimately responsible for all activities, including budget, sales, product development, and all other areas.
Years: 2006 to Present Employer: Undisclosed Title: Lecturer in Chemistry and Regulatory Affairs Officer Department: Science and Mathematics Department Responsibilities: For the faculty position, responsible for teaching organic as well as general chemistry courses, including both lecture and laboratory courses. Also responsible for the repair of laboratory equipment, aquisition of new analytical instrumentation, purchasing chemicals, and ordering supplies.

For the staff position, responsible for safety and regulatory compliance in the chemistry laboratory. Includes documenting procedures, maintainance of the chemical inventory, maintenance of the MSDS files, testing the safety equipment, as well as hazardous waste accumulation, storage, and disposal.
Years: 1996 to 2006 Employer: Vision-Ease Lens Title: Senior Research Chemist, Coating Engineering Manager, and Chemical Hygiene Officer Department: Research Responsibilities: Provide work direction for the research technicians and coordiate activities in the research laboratories.
Design experimentation such that it will be conducted in the most efficient and productive manner possible.
Devise new coatings and coating processes that are needed for future generations of superior products.
Assist in the design and synthesis of new photochromic dyes and hosts for those dyes.
Operate and maintain an FTIR microscope, gas chromatographs, and other analytical instrumentation,
Develop new test methods for finished products, coatings, inks, and incoming raw materials.
Write patent applications, invention disclosures, manufacturing instructions, and the chemical hygiene plan.
Prepare project reports and presentations for upper management.
Manage the coating engineering team to dramatically increase yields in manufacturing.
Train new personnel in troubleshooting the cleaning, coating, and curing operations.
Identify defects, accurately determine root causes, and promptly provide practical, permanent solutions.
Establish new coating operations at various foreign and domestic locations.
Identify new business opportunities and ascertain their accessibility with existing capabilities.
Establish and maintain regulatory compliance in the research laboratories.
Years: 1995 to 1996 Employer: Werneke Ink Title: Product Development Chemist Department: Research Responsibilities: Create new coatings for various papers and polymeric films.
Design new security features for financial instruments and other legal documents.
Attend customer trials.
Develop new methods for the safe and legal disposal of hazardous waste.
Years: 1994 to 1995 Employer: Dyno Polymers Title: Research Chemist Department: Research Responsibilities: Supervise the Research and Quality Control Departments.
Design new adhesive polymers for use in various wood products.
Develop new polymers for use as adhesives in laminates and paper overlays.
Create new catalysts for use in manufacturing a variety of forest products.
Oversee the scaleup of new products.
Assist manufacturing when technical challenges arise.
Provide technical assistance to customers at their manufacturing facilities.
Write project status reports and technical articles.
Years: 1984 to 1994 Employer: Cargill Title: Research Chemist, Chemical Hygiene Officer, Chair of the Quality Education Committee Department: Research Responsibilities: Design new polymers for waterborne, radiation curable, and multiple component systems.
Synthesize new polymers to identify process improvements and generate samples for testing.
Write manufacturing instructions, test methods, project reports, and other documentation.
Oversee the scaleup of new products through various levels of manufacturing.
Assist production personnel with technical difficulties in numerous manufacturing facilities.
Attend trade shows to provide technical assistance in the marketing of new products.
Provide work direction for a research assistant.
Maintain regulatory compliance in the research laboratory and promptly address issues as they arise.

International Experience

Years Country / Region Summary
Years: 2001 to 2001 Country / Region: Indonesia/West Java/Bandung Summary: Established a startup, high volume coating operation in a class 100 clean room environment. The critical cleaning processes employed various techniques, including ultrasonics, high pressure spray, aqueous detergents, organic solvents, and others. Both thermally cured and radiation cured coatings are employed in this manufacturing operation. In spite of adverse circumstances, all of the deadlines were met and the project was deemed a success. Subsequent defect analysis, troubleshooting, and process refinements have increased the yield to beyond the original expectations. These yield levels have since been maintained. This facility is still in operation today.
Years: 2000 to 2000 Country / Region: France/Il-de-France/Paris Summary: Installed a new spin coating operation for opthalmic lenses after specifying the equipment that was to be used for surface preparation, cleaning, curing, and testing. The project was successful.
Years: 1998 to 2000 Country / Region: Mexico/Baja California/El Sauzal Summary: Established an entirely new precision cleaning, coating, and curing operation. Qualified and installed new coating solutions as well as various equipment. This equipment included several curing units, and multiple HEPA filtered units for the dip application of the organometalic coatings. The operation was a complete success, meeting capacity and yield goals shortly after startup. Also installed a testing laboratory, complete with inspection equipment, an optical microscope, a gas chromatograph, and other testing equipment.

Career Accomplishments

Awards / Recognition
Vice-Presidents's Award - Vision-Ease Lens: the most significant contributions to the manufacturing operations. Fundamental improvements were made to the coating and related processes resulting in significant yield increases on multiple product lines.

Achiever's Circle Award - Cargill, executive and peer recognition for technical achievements: the origination of an idea for an unusual polyolefin and its development to commercial success. The resulting hydrolytically stable waterborne coatings have a shelf life of more than five years, whereas all previous products for this application fail within one year.
Publications and Patents Summary
Expert's publications include two technical articles as well as 11 US and foreign patents.

Language Skills

Language Proficiency
German

Fields of Expertise

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