Coated substrate and method for manufacturing the same

Abstract

A coated substrate and method for making the same are provided, the method including: securing a substrate to a pedestal; applying a first coating layer onto the substrate; wrapping the first coating layer around the substrate to substantially coat the substrate, the first coating layer having an excess coating of the first coating layer extending around the pedestal substantially away from the coated substrate; pulling the pedestal from the substrate; forming a tail portion from the excess coating of the first coating layer, the tail portion extending at an angle from a surface of the substrate; and sealing the tail portion to the first coating layer to encapsulate the substrate to form a coated substrate.

Description

Technical Field

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 050344, filed Jul. 10, 2020 (the entire content of which is incorporated herein by reference), U.S. Provisional Patent Application No. 63 / 062491, filed Aug. 7, 2020 (the entire content of which is incorporated herein by reference), and U.S. Provisional Patent Application No. 63 / 116940, filed Nov. 23, 2020 (the entire content of which is incorporated herein by reference).

[0002] The present disclosure generally relates to coating a substrate, and more particularly, to improved coated substrates, as well as systems and methods for manufacturing coated substrates.

Background Art

[0003] Substrates can be coated to provide resistance to environmental factors, such as water contamination, or to provide desired performance characteristics, such as controlled release that may be required based on the particular type of substrate. Coated substrates can be used for fertilizers, pharmaceutical tablets, and other applications. The components forming the substrate are susceptible to environmental influences and may degrade and lose effectiveness or cause undesirable effects when the substrate is exposed to the surrounding environment prior to its intended use. Coating the substrate may prevent undesirable effects due to environmental contamination or degradation. Also, a coated substrate may be designed to release over time if the coating is designed such that the substrate is exposed under certain desired conditions.

Summary of the Invention

[0004] In one embodiment, the Disclosure describes a method for manufacturing a coated substrate, comprising: fixing the substrate to a base; applying a first coating layer onto the substrate; wrapping the first coating layer around the substrate to substantially coat the substrate, wherein the first coating layer has excess coating of the first coating layer extending around the base toward the substantially coated substrate; pulling the base away from the substrate; forming a tail portion from the excess coating of the first coating layer, wherein the tail portion extends at an angle from the surface of the substrate; and sealing the tail portion to the first coating layer to encapsulate the substrate.

[0005] In one embodiment, the substrate is a solid core.

[0006] In one embodiment, the base is a pin. In one embodiment, the method includes heating the pin. The pin may be heated to a temperature higher than the melting point of the substrate, and fixing the substrate to the pin includes bringing the pin and the substrate into contact and embedding a portion of the pin into the substrate.

[0007] In one embodiment, before fixing the substrate to the base, a second coating layer is applied to the base to partially coat the base; the substrate is then delivered to the partially coated base. The second coating layer may be heated to thermoform the second coating layer around the base. In one embodiment, the tail portion is formed from the excess coating of the first coating layer and a portion of the second coating layer.

[0008] In one embodiment, the base includes a channel configured to provide vacuum suction for securing a substrate to the base.

[0009] In one embodiment, a solid core is fed into the cavity.

[0010] In one embodiment, the base extends into the cavity to bond with the substrate, and the base translates along its longitudinal axis without horizontal displacement.

[0011] In one embodiment, the edge of the first coating layer is applied to the lateral surface around the cavity, and the edge of the first coating layer is cut off from the lateral portion of the cavity.

[0012] In one embodiment, wrapping the first coating layer around the substrate includes drawing the first coating layer around the substrate.

[0013] In one embodiment, wrapping the first coating layer around the substrate includes blowing air along the periphery of the first coating layer.

[0014] In one embodiment, the tail portion is melted and laminated onto the first coating layer.

[0015] In one embodiment, the base material is a fertilizer, a pesticide, a fertilizer-pesticide combination product, a pharmaceutical tablet, a nutritional supplement tablet, an agricultural seed, a solid food article, or a water-soluble solid core.

[0016] Embodiments may include combinations of the above features.

[0017] In another embodiment, the disclosure describes a coated substrate comprising a substrate and a coating layer encapsulating the substrate, the coating layer comprising a principal portion covering a substantial surface area of ​​the substrate and a sealing region covering the remaining surface area of ​​the substrate, wherein the principal portion comprises a single, monopolymer film having an edge sealed by the sealing region.

[0018] In one embodiment, the substrate is a solid core. In another embodiment, the substrate is a fertilizer, a pesticide, a fertilizer-pesticide combination product, a pharmaceutical tablet, a nutritional supplement tablet, an agricultural seed, a solid food article, or a water-soluble solid core.

[0019] In one embodiment, the sealing region includes excess film of a single polymer film laminated on at least one of the substrate or the polymer film forming the coating layer.

[0020] In one embodiment, the coating layer comprises at least one of the following: polymer, polymer processing additive, mineral, pigment, pesticide, antimicrobial agent, ripening inhibitor, plant growth agent, micronutrient, pharmaceutically active ingredient, poly(vinyl alcohol), wax, adhesive resin, adhesive, fungicide, insecticide, nematicide, herbicide, microorganism, and / or fertilizer.

[0021] In one embodiment, the coating layer is at least one of the following: a thermoformable film, a vacuum formable film, a biodegradable film, a non-biodegradable film, a water-soluble film, a non-enteric film, and / or a polymer film containing at least one plant growth agent.

[0022] In one embodiment, the coating layer is between approximately 0.1% and 30% of the total weight of the substrate, preferably between 0.1% and 10%, and more preferably between 0.1% and 5%.

[0023] In one embodiment, the sealing region has a thickness greater than the main portion.

[0024] In one embodiment, the sealing area is less than 40% of the total surface area of ​​the coated substrate, preferably less than 20% of the total surface area of ​​the coated substrate, and more preferably less than 10% of the total surface area of ​​the coated substrate.

[0025] In one embodiment, the sealing region has substantially the same thickness as the main portion of the coating layer.

[0026] In one embodiment, the sealing region is formed by bonding the excess tubular portion of the coating layer to an adjacent portion of the coating layer layered on the substrate, and the tubular portion includes the edge of the coating layer.

[0027] In one embodiment, the seal area is formed by melting the excess tubular portion and laminating the melted excess tubular portion onto the coating layer.

[0028] In one embodiment, the seal area includes a reinforcing coating layer bonded to the edge of the coating layer.

[0029] In one embodiment, the supplementary coating layer is applied onto the first coating layer or directly onto the solid core, and the second coating layer at least partially encapsulates the solid core.

[0030] Embodiments may include combinations of the above features.

[0031] In a further aspect, the present disclosure describes a system for manufacturing a coated substrate, the system comprising a feeding device configured to feed a substrate into a receiving part, the receiving part having a mating pedestal; a first coating device configured to apply a coating layer to the receiving part; and a biasing device configured to bias the coating layer around the substrate and a part of the pedestal, the pedestal being movable relative to the mating receiving part via an opening defined in the mating receiving part, the pedestal being configured to move between an extended position where the pedestal extends into the mating receiving part to receive the substrate on the pedestal and a withdrawn position where the pedestal is withdrawn from the mating receiving part to separate the pedestal from the substrate and the coating layer to form a coated substrate having a tail portion; the system further comprising a sealing system for sealing the tail portion to the coating layer.

[0032] In one embodiment, the second coating device is configured to apply a second coating layer to each pedestal for partially coating the pedestal before the pedestal receives the substrate.

[0033] In one embodiment, each base is configured to translate along its longitudinal axis through an opening in a mating receiving portion without horizontal displacement in order to engage with or disengage from a base material.

[0034] In one embodiment, the receiving portion is a cavity defined on the surface of the plate.

[0035] In one embodiment, the base defines a channel configured to provide vacuum suction for securing the substrate to the base.

[0036] In one embodiment, the biasing device is a vacuum pump configured to generate vacuum pressure at the opening to bias the coating layer around a portion of the substrate and base.

[0037] In one embodiment, the biasing device is an air pump configured to pressurize air to bias the coating layer around a portion of the substrate and base.

[0038] Embodiments may include combinations of the above features.

[0039] In a further embodiment, the present disclosure describes a system for manufacturing coated substrates, the system comprising: a first rotating drum having a plurality of receiving parts positioned on the surface of the first rotating drum; a feed device configured to feed a plurality of substrates to the first rotating drum, each substrate being fed into one of the plurality of receiving parts, each receiving part having a mating base; and a first coating device configured to apply a coating layer to each of the plurality of receiving parts containing the substrates, the coating layer being applied as each of the plurality of receiving parts rotates beyond the first coating device. The system comprises a receiving device and a biasing device configured to bias a coating layer around a substrate and a portion of a base, wherein each mating base of a plurality of receiving portions is movable relative to its mating receiving portion through an opening defined in the mating receiving portion, and the base is movable to transition between an extended position in which the base extends into its mating receiving portion to receive a substrate on the base and an withdrawn position in which the base is withdrawn from its mating receiving portion, separating the base from the substrate and coating layer to form a coated substrate having a tail portion; the system further comprises a sealing system for sealing the tail portion to the coating layer.

[0040] In one embodiment, each base is configured to translate along its longitudinal axis through an opening in a mating receiving portion without horizontal displacement in order to engage with or disengage from a base material.

[0041] In one embodiment, the system comprises a second rotating drum having a plurality of receiving portions on the surface of the second rotating drum, the plurality of receiving portions of the second rotating drum positioned to receive a coated substrate having a tail portion from the first rotating drum, and the coated substrate positioned on the second rotating drum is positioned such that the tail portion is away from the second rotating drum.

[0042] In one embodiment, the system includes rollers for laminating the tail portion onto the coating layer.

[0043] In one embodiment, the biasing device includes a vacuum box configured to provide vacuum pressure to each receiving portion as it rotates from the feed device to a position adjacent to the second rotating drum.

[0044] In one embodiment, each base defines a channel that connects the vacuum box to the base.

[0045] In one embodiment, the biasing device includes an air pump configured to blow air around a portion of the substrate and base in order to bias the coating layer.

[0046] In one embodiment, the sealing system includes a heat source for thermally melting the tail portion into the coating layer.

[0047] In one embodiment, the system comprises a heating pin system for heating a base, the heating pin system comprising a heating element for heating the base to a desired temperature, and the base is a pin having a tip for contacting a substrate to bond the pin to the substrate by spot melting when the pin is in an extended position.

[0048] Embodiments may include combinations of the above features.

[0049] In a further embodiment, the present disclosure describes a system for manufacturing a coated substrate, the system comprising: a platform plate having one or more bases, each base having a mating receiving portion on a cavity plate, the cavity plate having one or more receiving portions positioned on the surface of the cavity plate, each receiving portion defining a cavity for receiving a substrate, and each receiving portion defining an opening extending through the cavity plate; a feeding device configured to feed a substrate to each base or its mating receiving portion; and a first coating device configured to apply a first coating layer to each of the plurality of receiving portions containing the substrate; The system comprises a first biasing device configured to bias a first coating layer around a substrate and a portion of each base, the platform plate being movable relative to a cavity plate to move each base simultaneously with respect to an opening defined in a mating receiving portion, the bases being movable to transition between an extended position in which the base extends into its mating receiving portion to receive a substrate on the base, and an withdrawn position in which the base is withdrawn from its mating receiving portion, separating the base from the substrate and the first coating layer to form a coated substrate having a tail portion, the system further comprising a sealing system for sealing the tail portion to the first coating layer.

[0050] In one embodiment, the system includes a first biasing member configured to bias the platform plate away from the cavity plate and move one or more bases to a withdrawn position.

[0051] In one embodiment, the biasing member is a spring positioned between the cavity plate and the platform plate.

[0052] In one embodiment, the system includes a second coating device positioned to apply a second coating layer to the receiving portion before the substrate is fed to the receiving portion by a feeding device.

[0053] In one embodiment, the system includes a second biasing device positioned to bias a second coating layer around a portion of each base before the substrate is fed to the receiving portion by a feeding device.

[0054] In one embodiment, the system comprises one or more detachable members fixed to each receiving portion and extending into a cavity for receiving a substrate.

[0055] In one embodiment, the base comprises a plurality of members that form a platform for receiving a substrate, the plurality of members being positioned on a platform plate such that they move between the detachment members as the base moves between an extended position and an extended position.

[0056] In one embodiment, the plurality of members comprises three members positioned at the three vertices of a triangle.

[0057] In one embodiment, the plurality of members comprises four members located at the four vertices of a cross shape.

[0058] In one embodiment, the platform plate defines a plurality of vacuum openings, each generally positioned at the center of a plurality of members, and each opening is configured to transmit vacuum pressure from a vacuum pressure source to a mating receiving portion when the plurality of vacuum openings are aligned with a mating opening in the cavity plate.

[0059] In one embodiment, each base is configured to translate along its longitudinal axis through the opening of its mating receiving portion without horizontal displacement in order to engage with or disengage from the base material.

[0060] In one embodiment, the biasing device includes an air pump configured to blow air to bias the coating layer around a portion of the substrate and base.

[0061] In one embodiment, the system includes an actuator coupled to at least one of the cavity plate and the platform plate, which moves the cavity plate relative to the platform plate, thereby simultaneously moving each base between an extended position and a withdrawn position.

[0062] Embodiments may include combinations of the above features.

[0063] Further details of these and other aspects of the subject matter of this application will become apparent from the detailed description and drawings contained herein.

[0064] Please refer to the attached drawing. [Brief explanation of the drawing]

[0065] [Figure 1] An exemplary side view of a coated substrate is shown. [Figure 2A] Figure 1 shows a side view of the precursor of the coated substrate. [Figure 2B] Figure 2A shows a fragmentary diagram of an exemplary tail portion of the coated substrate. [Figure 3] This shows an exemplary receiving section of a system for manufacturing coated substrates. [Figure 4] An exemplary base of an exemplary system for manufacturing coated substrates is shown. [Figure 5] Figure 3 shows an exemplary system comprising a receiving section and a base shown in Figure 4 at its withdrawal position. The substrate is received within the receiving section. [Figure 6] Figure 4 shows the substrate positioned on the base in its extended position. [Figure 7] Figure 6 shows the coating layer applied to the substrate and receiving portion. [Figure 8] Figure 7 shows the application of vacuum pressure or pneumatic pressure to the coating layer. [Figure 9]An exemplary precursor of the coated substrate and the base of the exemplary system shown in Figure 8 at its extraction position are shown. [Figure 10] Figure 9 shows an exemplary precursor that has been repositioned within another receiving section. [Figure 11] Figure 10 shows an exemplary precursor and a heating device for heating the tail portion of the exemplary precursor. [Figure 12] Figure 11 shows a roller for laminating the tail portion shown, and the resulting exemplary coated substrate. [Figure 13] This shows several exemplary pedestals for a system for manufacturing coated substrates. [Figure 14] Figure 13 shows an exemplary system for manufacturing a coated substrate with a base. [Figure 15] Figures 3-12 show exemplary equipment comprising a system for manufacturing coated substrates. [Figure 16] Another exemplary apparatus is shown, comprising the system depicted in Figures 3-12, for manufacturing coated substrates. [Figure 17] An example of coating equipment is shown. [Figure 18] Another system for manufacturing coated substrates is shown. Figures 18 and 19 show exemplary receiving and pedestal parts of the system. Figure 20 shows a substrate received on the pedestal shown in Figures 18 and 19. Figures 21–23 show coating layers applied to the substrate in Figure 20 to form exemplary precursors. [Figure 19] Another system for manufacturing coated substrates is shown. Figures 18 and 19 show exemplary receiving and pedestal parts of the system. Figure 20 shows a substrate received on the pedestal shown in Figures 18 and 19. Figures 21–23 show coating layers applied to the substrate in Figure 20 to form exemplary precursors. [Figure 20]Another system for manufacturing coated substrates is shown. Figures 18 and 19 show exemplary receiving and pedestal parts of the system. Figure 20 shows a substrate received on the pedestal shown in Figures 18 and 19. Figures 21–23 show coating layers applied to the substrate in Figure 20 to form exemplary precursors. [Figure 21] Another system for manufacturing coated substrates is shown. Figures 18 and 19 show exemplary receiving and pedestal parts of the system. Figure 20 shows a substrate received on the pedestal shown in Figures 18 and 19. Figures 21–23 show coating layers applied to the substrate in Figure 20 to form exemplary precursors. [Figure 22] Another system for manufacturing coated substrates is shown. Figures 18 and 19 show exemplary receiving and pedestal parts of the system. Figure 20 shows a substrate received on the pedestal shown in Figures 18 and 19. Figures 21–23 show coating layers applied to the substrate in Figure 20 to form exemplary precursors. [Figure 23] Another system for manufacturing coated substrates is shown. Figures 18 and 19 show exemplary receiving and pedestal parts of the system. Figure 20 shows a substrate received on the pedestal shown in Figures 18 and 19. Figures 21–23 show coating layers applied to the substrate in Figure 20 to form exemplary precursors. [Figure 24] Figures 18-23 show exemplary equipment comprising the system. [Figure 25] An exemplary apparatus is shown, comprising a system for manufacturing coated substrates. [Figure 26] Figure 25 shows an example platform plate of the system. [Figure 27] Figure 25 shows an exemplary cavity plate of the system. [Figure 28] Figure 26 shows a cross-sectional view of an exemplary platform plate. [Figure 29] Figure 27 shows a cross-sectional view of an exemplary cavity plate. [Figure 30]Figure 27 shows a cross-sectional view of an exemplary cavity plate positioned on an exemplary platform plate. [Figure 31] Figure 30 shows a cross-sectional view of an exemplary cavity plate positioned on a platform plate, which is coated with a coating layer. [Figure 32] Figure 30 shows a cross-sectional view of an exemplary cavity plate positioned on a platform plate after being partially coated with a coating layer. [Figure 33] Figure 30 shows a cross-sectional view of an exemplary cavity plate positioned on a platform plate after being partially coated with a coating layer and receiving a substrate. [Figure 34] Figure 30 shows a cross-sectional view of an exemplary cavity plate positioned on a platform plate, having an exemplary precursor positioned on the base of the platform plate. [Figure 35] Figure 34 shows an exemplary precursor. [Figure 36] Figure 35 shows an exemplary coated substrate formed from the precursor. [Figure 37] An isometric view of an exemplary cavity plate for a system for manufacturing coated substrates is shown. [Figure 38] An isometric view of an exemplary platform plate for a system for manufacturing coated substrates with a base is shown. [Figure 39] Figure 38 shows an isometric view of the cavity plate in Figure 37, which overlaps with the platform plate in Figure 38. [Figure 40] Figure 37 shows an exemplary top view of the receiving portion and the detaching member of the cavity plate. [Figure 41] Figure 40 shows an exemplary cross-sectional view of the receiving portion and base along line AA. [Figure 42-43] An exemplary top view of the receiving portion and the detaching member is shown. [Figure 44]Figure 38 shows a cross-sectional view of the platform plate, which has a base member positioned around the opening of the platform plate. [Figure 45] Figure 39 shows a cross-sectional view of a portion of the cavity plate that overlaps with the platform plate. [Figure 46] Figure 39 shows a cross-sectional view of a portion of the cavity plate that overlaps with the platform plate, which has a base material positioned on a base component. [Figure 47] Figure 39 shows a cross-sectional view of a portion of the cavity plate that overlaps with the platform plate, where the base material, which is mounted on the base, is coated with a coating layer. [Figure 48] Figure 45 shows a portion of the cavity plate overlapping with the platform plate, which has a substrate mounted on a base coated with a coating layer, and a cross-sectional view of the cutting tool. [Figure 49] Figure 45 shows a cross-sectional view of a portion of the cavity plate that overlaps with the platform plate, which has a precursor mounted on a base. [Figure 50] Figure 49 shows a cross-sectional view of a portion of the cavity plate that overlaps with the platform plate, which has a precursor separated from the base. [Figure 51] Figure 2A shows an exemplary perspective cross-section of the tail portion of the precursor. [Figure 52] Figure 2A shows a perspective cross-section of another exemplary tail portion of the precursor shown. [Figure 53] Figure 2A shows a perspective cross-section of another exemplary tail portion of the precursor shown. [Figure 54] Figure 1 shows a fragmentary diagram illustrating an exemplary sealing area of ​​a coated substrate. [Figure 55] This is a fragmentary diagram of another exemplary sealing area of ​​the coated substrate shown in Figure 1. [Figure 56] This is a fragmentary diagram of another exemplary sealing area of ​​the coated substrate shown in Figure 1. [Figure 57]This is a flowchart illustrating the manufacturing method of an exemplary coated substrate. [Figure 58] A schematic diagram of a base polymer film coated with a moisture barrier coating is provided. [Modes for carrying out the invention]

[0066] This disclosure relates to coated substrates and systems / methods for manufacturing the same, which provide improved resistance to environmental contamination, improved performance characteristics, and / or ease of manufacture.

[0067] The exemplary substrates described herein may be fertilizer granules, fertilizer tablets, biofertilizer tablets, biocidal tablets or granules, salt granules, herbicide granules or tablets, fungicide granules or tablets, insecticide granules or tablets, other pesticide granules or tablets, granular or tablet-form fertilizer-pesticide combination products, salt tablets, inorganic chemical granules, agricultural seeds, animal feed products, detergent tablets or granules, pharmaceutical or nutritional supplement tablets, pharmaceutical or nutritional supplement capsules, confectionery, water treatment tablets, fungicides, biostimulants, inoculants, solid food articles, fruits, vegetables, or water-soluble solid cores.

[0068] In this disclosure, terms such as “maximize,” “minimize,” and “optimize” may be used, but it should be understood that such terms may be used to refer to improvements, adjustments, and refinements that are not strictly limited to maximum, minimum, or optimal.

[0069] The terms “to be fixed to,” “to be connected to,” or “to be joined to” can include both direct joining (two elements joined to each other are in contact with each other) and indirect joining (at least one additional element is placed between the two elements).

[0070] The term “substantially” as used herein may be applied to modify any quantitative expression that may be permissibly varied without resulting in a change in the fundamental function of the subject matter. For example, a drive shaft such as those disclosed herein having a circular cross-section may permissibly have a somewhat non-circular cross-section within the scope of the invention, provided that its rotational driving capability does not change significantly.

[0071] The terms "e.g.," "etc.," "for instance," and "or," and grammatically related terms, unless otherwise specified, indicate unrestricted, non-exclusive substitutions.

[0072] The term "includes" and grammatically related terms, unless otherwise specified, mean "includes, but is not limited to."

[0073] The articles "a," "an," and "the" are intended to be interpreted as referring to both singular and plural nouns, unless the context clearly indicates otherwise.

[0074] "Coating composition" means a mixture or blend of two or more components. A coating composition may contain two or more of the following: polymers, processing additives, plant growth agents, plasticizers, waxes, co-initiators or curing catalysts, antioxidants, adhesives, mineral fillers, oxo / photobiodegradable additives, anti-tacks, pigments, or lubricants. The form of a "coating composition" is understood to be a liquid mixture of different components, which may be dissolved or dispersed in a solution, or may be an emulsion / microemulsion.

[0075] In this specification, the terms “melt” or “soften” used to define a polymer mean that the polymer is flexible enough to be thermoformed or vacuum-formed.

[0076] The term "coating layer" refers to a layer of polymer film of a desired coating thickness applied to a substrate. The terms "coating layer," "polymer film," and "polymer coating" are used interchangeably and mean the same thing unless otherwise defined.

[0077] The terms "effective surface area," "substantially coated," or "substantially coated" mean that the coating layer covers more than 50% but less than 100% of the surface area of ​​the substrate being coated.

[0078] The terms "excess coating layer" and "tail portion" are used interchangeably and refer to the portion of the polymer film that extends away from the surface of the substrate, adhering to the polymer film covering the surface area. The excess coating layer does not directly cover the surface of the substrate being coated.

[0079] The term “seal region” refers to a portion of a coating layer having an area defined by the size of an excess coating layer that is sealed and bonded to the coating layer covering the substrate and / or the surface of the substrate in order to encapsulate and seal the substrate. In one example, the seal region is formed by the melt fusion of the excess coating layer, where the excess coating layer melts and fuses with itself under heat to form the seal region. In another example, the excess coating layer may be bonded to the coating layer with an adhesive. When viewed under a microscope such as a SEM, the seal region may appear distinct from the rest of the coating layer. The terms “seal region” and “seal spot” may be used interchangeably herein.

[0080] The term "multi-layer coating" refers to a coating layer having multiple polymer film layers. For example, a first coating layer with a thickness of 30 microns may consist of a 20-micron thick PLA (polylactic acid) film and a 10-micron thick LDPE (low-density polyethylene) film. A co-extruded multi-layer film of multiple polymers is an example of a multi-layer coating layer. The coating layers described herein may constitute a multi-layer coating layer.

[0081] The term "lamination" refers to the bonding of a polymer film to itself or to another surface via heat, pressure, or adhesive. Lamination includes heat lamination and cold lamination.

[0082] The term "heat lamination" refers to the melting and fusing of two polymer films using heat.

[0083] The term "cold lamination" refers to the process of laminating two films using only pressure or adhesive. Generally, two films with an adhesive layer are pressed together, and the adhesive acts as a binder to join the two films.

[0084] The term "polymer" refers to a high-molecular-weight compound prepared by polymerizing identical or different monomers. The general term polymer includes homopolymers, a term typically used to refer to polymers prepared from only one type of monomer.

[0085] The terms "biopolymer" or "natural polymer" refer to high-molecular-weight compounds produced from plants or animals.

[0086] The terms "copolymer" and "interpolymer" refer to polymers prepared by the polymerization of at least two different types of monomers. These general terms include the conventional definition of copolymer, i.e., a polymer prepared from two different types of monomers, and the broader definitions of copolymer and interpolymer, i.e., polymers prepared from more than two different types of monomers, such as terpolymers, tetrapolymers, etc.

[0087] The term "blend" means a composition of two or more materials. Such a blend may or may not be miscible. Such a blend may or may not undergo phase separation. Such a blend may or may not contain one or more domain configurations, as determined by transmission electron spectroscopy, light scattering, X-ray scattering, and other methods known in the art.

[0088] The term "coating apparatus" means any commercially available apparatus capable of applying a coating layer to a substrate. A coating apparatus could be a hot melt extruder and die capable of producing a polymer film layer of a desired thickness; a hot melt polymer spray capable of producing a spray of hot melt polymer; a slot die coater capable of producing a coating layer; a slot nozzle capable of producing a coating layer; a curtain coater capable of producing a coating layer; an ultraviolet or EB coating apparatus capable of curing a coating layer using an electron beam or ultraviolet lamp; or a thermal film laminator capable of heating a polymer film through a heat source and applying or laminating it to a surface.

[0089] The term "coating station" refers to a location where coating equipment is installed and a coating layer is applied to a substrate.

[0090] The terms “off-the-shelf polymer film” or “polymer film” refer to polymer films manufactured using any of the following commercially available film manufacturing processes: cast film extrusion, blow film extrusion processes, or cast solutions. Polymer films may contain any processing aids or additives necessary to impart the desired chemical or mechanical properties to the polymer film.

[0091] The term "fertilizer" means any commercially available fertilizer granules, fertilizer tablets, fertilizer-pesticide tablets, or any chemical used to promote plant growth, in any form or size.

[0092] The term "fertilizer of any shape or size" means that the fertilizer to be coated may be of any shape, for example, compressed chemicals produced by a dry-compression process, tablets, spikes, briquettes, spheres, spheroids, capsules, or chemical salt crystals that do not have a specific shape.

[0093] The term "grid pattern" refers to substrates that are arranged and held at a certain distance from one another.

[0094] The term "cavity" refers to a housing for holding a substrate.

[0095] The term "base" refers to one or more columns within a cavity on which a substrate is placed and can be held in place by, for example, friction, gravity, or vacuum pressure. One or more columns may define the platform on which the substrate is received.

[0096] The term "conveyor belt system" is understood to refer to a motor-driven flat conveyor belt with a cavity and base plate joined together.

[0097] The terms “hot pin,” “hot needle,” or “heating platform” refer to a pin, platform, or column within a cavity that can be heated via an internal or external heat source to raise the temperature of the pin or platform.

[0098] The term "pin" refers to a component that has a sharp end for bonding to a base material.

[0099] The term "spot melting" refers to an area of ​​an object that melts or softens due to heat, generally less than 50% of the entire object.

[0100] The term "melt fusion" means that a substrate or particulate matter is joined together by melting one material to another.

[0101] The term "embedded" means that a portion of the pin is pressed into the surface of the substrate and bonded to it.

[0102] Various embodiments will be described with reference to the drawings.

[0103] Figure 1 shows an exemplary coated substrate 105. The coated substrate 105 comprises a substrate 101 and a coating layer 102 enclosing the substrate 101. The coating layer 102 comprises a main portion 102A and a sealing region 104. The main portion 102A may be a single unit piece of polymer having an edge sealed by the sealing region 104. In one example, the main portion 102A may be stretched around the substrate 101 to cover a substantial surface area of ​​the substrate 101. The coating layer 102 may have a generally uniform thickness around the surface of the substrate 101. In one example, the main portion 102A of the coating layer 102 covers more than 60% of the surface of the substrate 101. In another example, the main portion 102A of the coating layer 102 covers more than 75% of the surface of the substrate 101. In yet another example, the main portion 102A of the coating layer 102 covers more than 90% of the surface of the substrate 101. In another example, the main portion 102A of the coating layer 102 covers 80% to 90% of the surface of the substrate 101. In yet another example, the main portion 102A of the coating layer 102 covers 90% to 95% of the surface of the substrate 101. As shown in Figure 1, the main portion 102A is a single unit piece of polymer film extending to a sealing region 104 of the coating layer 102 that encloses the remaining portion of the substrate 101 not enclosed by the main portion 102A. As described herein, the sealing region 104 may be formed by laminating the excess coating layer 102 onto itself, the main portion 102A, and / or the substrate 101.

[0104] In one embodiment, the sealing area 104 of the coated substrate 105 may have a thickness generally greater than the main portion 102A of the coating layer 102. In another embodiment, the coated substrate 105 has a sealing area of ​​less than 40% of the total surface of the coated substrate. In yet another embodiment, the coated substrate 105 has a sealing area of ​​less than 20% of the total surface of the coated substrate. In yet another embodiment, the coated substrate 105 has a sealing area of ​​less than 10% of the total surface of the coated substrate. In one embodiment, the sealing area 104 may have an area of ​​approximately the same size as the base on which the coated substrate 105 is formed.

[0105] In one embodiment, the coated substrate 105 comprises an auxiliary coating layer applied on or directly onto the substrate, the second coating layer at least partially enclosing the substrate.

[0106] Figure 36 shows another exemplary coated substrate 105B. Similar to coated substrate 105, coated substrate 105B comprises a coating layer 102-1 enclosing the substrate 101. The coating layer 102B comprises a main portion 102B and a sealing region 104B. The main portion 102B may be a single unit piece of polymer with an edge sealed by the sealing region 104B. In one example, the main portion 102B may be extended around the substrate 101 to cover a substantial surface area of ​​the substrate 101. The coating layer 102-1 may have a generally uniform thickness around the surface of the substrate 101. Coated substrate 105B also comprises a reinforcing coating layer 108 bonded to the sealing region 104B. In one embodiment, the reinforcing coating layer 108 may be melt-fused or attached to the sealing region 104B. In another embodiment, coated substrate 105B has a sealing region 104B of less than 40% of the total surface of the coated substrate. In yet another embodiment, the coated substrate 105B has a sealing area of ​​less than 20% of the total surface of the coated substrate. In yet another embodiment, the coated substrate 105B has a sealing area of ​​less than 10% of the total surface of the coated substrate. In one embodiment, the sealing area 104B may have an area of ​​approximately the same size as the base on which the coated substrate 105B is formed.

[0107] The base material 105 may be a solid core. Non-limiting examples of solid cores include organic fertilizers, inorganic fertilizers, mineral fertilizers, natural fertilizers, biofertilizers, organic mineral fertilizers, pesticides, fertilizer-pesticide products, compound fertilizer products, fertilizers of any shape or size, biostimulants, inoculants, plant growth promoters, agricultural seeds, biocides, chemical salts, water treatment chemicals, pharmaceutical tablets, nutritional supplements, confectionery, and solid cores of any shape or size.

[0108] In one embodiment, the coated substrate 105 has coating layers 102, 102-1, 103C comprising at least one of a polymer, a polymer processing additive, a mineral, a pigment, and / or a plant growth agent (PGA). In some embodiments, the coating layer 102 may be water-soluble. In some embodiments, the coating layer is between about 0.1% and 30% of the total weight of the substrate 101, preferably between 0.1% and 10% of the total weight of the substrate 101, and more preferably between 0.1% and 5% of the total weight of the substrate 101.

[0109] In another embodiment, the coating layers 102, 102-1, and 103C may be commercially available thermoplastic polymers for film extrusion, such as commercially available extrusion coating grade polymers. Examples of commercially available grade polymers for melt extrusion in film form are listed in the following publications: Biopolymer: Processing & Products / By Michael Niaounakis / PDL Handbook Series / William Andrew, Inc (2014), and Handbook of Biodegradable Polymers-Synthesis Characterization and Application / edited by Andreas Lendlein and Adam Sissoon / Published by Wiley VCH (2011).

[0110] In another embodiment, coating layers 102, 102-1, 103C may comprise thermoplastic polymers selected from: polyacetal, nylon, polyethylene (PE) of different molecular weights and densities, polypropylene (PP), polystyrene (PS), polyvinyl chloride (PVC), polymethyl methacrylate (PMMA or acrylic), acrylonitrile butadiene styrene (ABS), polycarbonate (PC) polyester, polyethylene terephthalate (PET), polybutylene terephthalate (PBT) polyamide (PA or nylon), polyphenylene sulfide (PPS), polyphenylene oxide / polystyrene blends, polyetherimide (PEI), polysulfone (PSO), and blends and copolymers thereof.

[0111] In another embodiment, the coating layers 102, 102-1, 103C may comprise a thermoplastic elastomer polymer selected from: styrene-butadiene rubber, butadiene rubber, isoprene, butyl rubber, chloroprene rubber, nitrile rubber, ethylene-propylene rubber (EPM and EPDM), silicone rubber, polyurea, polyurethane, or blends or derivatives thereof.

[0112] In another embodiment, the coating layers 102, 102-1, and 103C may comprise a biodegradable thermoplastic polymer selected from: polyglycolides, poly(lactide-coglycolides) (PI-GA), poly(butylene succinate) (PBS) and its copolymers, poly(P-dioxanone) (PDO or PPDO), polycaprolactone (PCL), polyhydroxyalkanoates (PHA), polyhydroxybutyrate (PHB), polyhydroxyvalerate (PHV), polylactic acid (PI-A), biodegradable polycarbonates, polyvinyl alcohol (PVOH), polyvinyl acetate (PVA), and their copolymers and derivatives.

[0113] In another embodiment, coating layers 102, 102-1, 103C may comprise biodegradable or non-biodegradable thermoplastic polymers, thermoplastic elastomers, thermosetting polymers, alkyd resins, UV or electron beam curable resins, biopolymers, recycled polymers and natural polymers of natural or synthetic origin, copolymers or blends thereof. In yet another embodiment, the biopolymer or natural polymer may be selected from: cellulose derivatives, polysaccharides, chitin and chitosan polymers, proteins or gelatin. Numerous commercially available products exist for use in coating applications intended by this disclosure.

[0114] Exemplary commercially available grade biodegradable polymers for the coating layers described herein may include: NatureWorks® 2000 series: 2003D TDS; NatureWorks® 3000 series: 3001D SDS, 3052D SDS, 3251D SDS, 3801X SDS; NatureWorks® 4000 series: 4032D TDS, 4043D TDS, 4060D TDS; NatureWorks® 6000 series: 6060D TDS, 6201D TDS, 6202D TDS, 6204D TDS, 6400D TDS, 6251D TDS, 6252D TDS, 6302D TDS, 6751D TDS, 6752D TDS; NatureWorks® 7000 series: 7001D TDS, 7032D PLA resin from TDS, recycled PLA such as Galactic (Belgium), LOOPLA® and Galacid® from Futerro Total / Galactic (Belgium), PLA / PCL blends: VYLOECOL BE-4001, VYLOECOL BE-600, VYLOECOL BE-910, VYLOECOL HYD-306, VYLOECOL BE-450, VYLOECOL BE-410, VYLOECOL HYD-006 from Toyobo (Japan); Ecodear® series from Toray (Japan), blends of PLA (Nature-Works)'s PLA / polyether copolymer BIO-FLEX® series; copolyester blends from FKuR Kunststoff GmbH (DE); polycaprolaton: Capa™ 6000 and 7000 series, Celgreen PH, Placel® 200 series. Placcel® 300 series, Placcel® F series (macromonomer), Placcel® H1P (Mw 10,000), Tone® series from DOW;Products from Showa Polymer (Japan): PBS (polybutylene succinate) trade name Bionolle™ 1000, and PBSA (polybutylene succinate adipate) trade name Bionolle™ 3000 series; PBSA trade name Skygreen™ SG200 from SK Chemicals (Korea); PBSL (polybutylene succinate-colactate) trade names GS Pla® AD92W, GS Pla® AZ91T, and GS Pla® GZ95T from Mitsubishi Chemical (Japan); PES-poly(ethylene succinate) trade name Lunare SE® from Nippon Shokubai (Japan); PBAT (polybutylene adipate-coterephthalate) Ecoflex® series from BASF (Germany); and Origo-Bi® (formerly Eastar Bio®) from Novamont (Italy).

[0115] Exemplary commercially available thermoplastic starch-based starch polymers for the coating layers described herein may include: Mater-Bi® from Novamont (IT), Plantic® HP from Plantic (AU), Plantic® R1 from Biotec (Germany), BIOPLAST GF 106 / 02, BIOPLAST GS 2189, BIOPLAST WRAP 100, BIOPLAST TPS from Biotec (Germany), Biolice® from Limagrain (France), Solanyl® BP, Solanyl® C1xxx grades (injection molding): C1001, C1201, C1203, Solanyl® C2xxx grades (thermoformed grade): C2201, Solanyl® C8xxx grades (blown film): C8101, C8201.

[0116] Exemplary commercially available thermoplastic chitin polymers for the coating layers described herein are available from: Primex Corporation, Iceland (IS), Biopolymer Engineering, Inc. (USA), Biopolymer Technologies, Inc. (USA), and CarboMer, Inc. (USA).

[0117] The experimental commercial-grade poly(vinyl alcohol) (PVOH) for the coating layers described herein may include: high-purity PVOH available from Nippon Synthetic Chemical Industry Co. Ltd. (Japan) under the trade names GOHSENOL EG series: EG-05, EG-05P, EG-40, and EG-40P; anionic PVOH available from Nippon Synthetic Chemical Industry Co., Ltd. (Japan) under the trade names GOHSENAL series: T330H, T-300, and T-350; and also from Nippon Synthetic Chemical Industry Co., Ltd. (Japan) under the trade name ECOMATY series: WO-320R Hydrophilic modified PVOH available under WO-320N; modified PVOH with sulfone groups (-SO3X groups) in the side chain available from Nippon Synthetic Chemical Industry Co., Ltd. (Japan) under the trade name GOHSERAN series; low-saponification hydrophilic PVOH available from Nippon Synthetic Chemical Industry Co., Ltd. (Japan) under the GOHSEFIMER series; Mowiol® / Kuraray POVAL® Mowiflex TC®, Exceval, Kuraray POVAL® K, Kuraray POVAL® L, Kuraray POVAL® LM, and Kuraray POVAL® R from Kuraray (Japan); PVOH-coplasticizer (polyalkylene oxyacrylate) under "VINEX®" from Air Products & Chemicals; and Nichigo G-Polymer powder type from Nippon Synthetic Chemical Industry Co., Ltd. (Japan) under the trade name Nichigo G-Polymer: AZF8035W OKS-6026 OKS-1011 OKS-8041 PVOH under OKS-8049, OKS-1028, OKS-1027, OKS-1109, amorphous; pellet type: OKS-8049P, OKS-8084P, OKS-8042P.

[0118] In one embodiment, the coating layer may include waxes such as paraffin wax, Fischer-Tropsch wax, by-product polyethylene wax, high-density low-molecular-weight polyethylene wax, microcrystalline wax, plant wax, and combinations thereof.

[0119] In one embodiment, the coating layer may include an adhesive resin or adhesive. The adhesive resin or adhesive may be used to modify the tackiness, wettability, and adhesion of the coating layer. Exemplary adhesive resins or adhesives include low molecular weight polymers based on aliphatic or aromatic hydrocarbons, rosin, rosin esters, terpenes, styrene or phenol derivatives, styrene-terpenes, terpene-phenol resins, aliphatic hydrocarbon resins, aromatically modified aliphatic resins, aromatic hydrocarbon resins, α-methylstyrene resins, hydrogenated hydrocarbon resins, and aromatically modified hydrocarbon resins, or any combination thereof. The formulation may include stabilizers and antioxidants to prevent premature viscosity changes and char or gel formation that could lead to equipment shutdown.

[0120] In another embodiment, the coating layers 102, 102-1, 103C contain one or more plant growth agents (PGAs) dispersed in a polymer film matrix. The PGAs may be configured to be released by the decomposition of the film or by leaching from the film matrix upon contact with a liquid medium or water. The release rate of the PGAs is controlled by the biodegradation rate from the polymer film matrix and the leaching rate of the PGAs. Polymer films with different biodegradation rates may have different PGA release rates, and water solubility or miscibility of the PGAs and the polymer also affects the release rate of the PGAs from the film matrix. In some embodiments, the PGAs are applied together with a surfactant that facilitates the release of the PGAs from the film matrix.

[0121] In some embodiments, the coating layers 102, 102-1, and 103C contain an antimicrobial or anti-maturation agent blended / mixed with the polymer film matrix. The antimicrobial or anti-maturation agent may be released sustainably through the polymer film. For example, the antimicrobial-filled polymer film may be coated onto a substrate intended for human consumption, such as fruits and vegetables.

[0122] In some embodiments, coating layers 102, 102-1, and 103C contain a pharmaceutically active ingredient (PAI) dispersed or dissolved in the polymer matrix. The PAI may be mixed into the polymer via hot-melt extrusion, and the hot-melt extruded film layer can then be applied to the surface of a substrate, such as a pharmaceutical dosage form, such as a tablet, capsule, caplet, or softgel tablet / capsule. Polymer films for hot-melt extrusion can be produced from dry pelletized pharmaceutical-grade polymers extruded into a thermoformable film. Exemplary polymers for use in pharmaceutical applications include non-enteric polymers, hypromellose, hydroxyethylcellulose, hydroxyethylmethylcellulose, sodium carboxymethylcellulose, hydroxypropylcellulose, polyethylene glycol, and ethylcellulose. Polymers for enteric coatings may include hypromellose phthalate, polyvinyl acetate phthalate, cellulose acetate phthalate, polymethacrylate, and shellac.

[0123] In some embodiments, the coating layers 102, 102-1, 103C are styrene block copolymers, polyolefins (e.g., amorphous and crystalline polyolefins including homogeneous and substantially linear ethylene / α-olefin interpolymers), ethylene interpolymers and copolymers including, for example, ethylene-vinyl acetate, ethylene-vinyl acetate, ethylene-acrylic acid, ethylene-methacrylic acid, ethylene-methyl acrylate, ethylene-ethyl acrylate and ethylene-n-butyl acrylate and derivatives (e.g., incorporating at least two comonomers), polyacrylic acid, polymethacrylic acid The materials include acids, polyacrylates, polyvinyl acetate, polylactic acid, polylactide, caprolactone polymers, poly(hydroxybutyrate / hydroxyvalerate), polyvinyl alcohol, polyesters, copolyesters (e.g., biodegradable copolyesters), poly(ethylene oxide) polyetheramides, polyester ether block copolymers, polyvinylpyrrolidone, polyvinylpyrrolidone-vinyl acetate copolymers, polyetheroxazolines, polyvinyl ethers (e.g., polyvinyl methyl ether), polyamides, polyurethanes, polyacrylamides, polyesters, and combinations and blends thereof.

[0124] In some embodiments, the coating layers 102, 102-1, and 103C may comprise a plurality of polymer film layers that are pre-laminated together to reduce shrinkage of the coating layers during application to the substrates described herein.

[0125] Figure 2A shows a precursor 200 relative to the coated substrate 105 illustrated in Figure 1. The sealing region 104 comprises an excess coating layer 103 of the coating layer 102 extending away from the surface of the substrate 101. As illustrated, the excess coating layer 103 is a continuous extension of the coating layer 102 and may extend away from the surface of the substrate 101 at any angle, for example, approximately perpendicular to the surface of the substrate 101 as shown in Figures 2A and 2B. In one embodiment, the excess coating layer 103 shown in Figure 2B may have a generally cylindrical shape before being deformed into the sealing region 104. As described below with respect to a manufacturing method for producing the coated substrate 105, the excess coating layer 103 may be bonded to the substrate 101 and / or main portion 102A, for example, by lamination. In one embodiment, the sealing region 104 is formed by bonding the excess coating layer 103 of the coating layer 102 to the main portion 102A and / or the substrate 101 adjacent to the excess coating layer 103. The excess coating layer 103 may have a generally tubular shape with an edge that defines the opening 103A of the coating layer. The sealing region 104 may also be formed by melting the excess coating layer 103 and laminating it to the main portion 102A of the coating layer and / or the substrate 101.

[0126] Figures 3–12 show an exemplary system 300 for manufacturing a coated substrate as described herein. The system 300 may include a feed device (currently shown) configured to feed the substrate 101 into a receiving section 203, each receiving section 203 having a mating base. The bases may have various designs, such as the pin 301 shown in Figure 4, the base 409 shown in Figures 18–22, the base 203 shown in Figure 26, and the base 2121 shown in Figure 38. The feed device may be any suitable device for delivering the substrate to the receiving sections 203 of the system 300. In one example, the feed device may be a hopper and / or may include a vibrating feed device having aligned channels for feeding the substrate 101 into one or more receiving sections 203 of the system 300. The receiving section 203 may define a cavity 203A for receiving the substrate 101. As shown in Figures 3 and 5, the receiving portion 203 may define an opening 202 having a region configured to receive and hold the substrate 101. Each base is movable relative to its mating receiving portion 203 through the opening 202, and each base is configured to have an extended position in which the base extends into its mating receiving portion to engage with a substrate on the base. In one example, the base is configured to translate along its longitudinal axis through the opening 202 of the mating receiving portion without horizontal displacement in order to engage with or disengage from the substrate 101. The receiving portion 203 may have raised edges 201 on its periphery that define a lateral surface for receiving the coating layer. A first coating device 401, such as a polymer film extruder, may be configured to apply the coating layer 102 to the receiving portion 203. As shown in Figure 7, the substrate 101 may be received by the receiving portion 203 before the application of the coating layer 102 to the receiving portion 203. A biasing device may be provided which is configured to bias a polymer coating around a substrate and a portion of the base. As shown in Figure 8, in one example the biasing device may be a vacuum pump configured to apply vacuum pressure (shown as line A) to pull the coating layer 102 around the substrate 101 and a portion of the base.In one example, the vacuum suction airflow may be maintained between 20 cubic feet / min (CFM) and 200 CFM (ft³ / min) through the opening 202 (depending on the thickness of the polymer film). In another example, the biasing device may also be an air pump configured to apply pressure (shown as line B in Figure 8) to bias the coating layer 102 around the substrate 101 and a portion of the base. Once the coating layer 102 has wrapped around the substrate 101 and a portion of the base, the base may be withdrawn from its mating receiving portion 203, separating the base from the substrate 101 and the coating layer 102 to form a coated substrate with a tail portion 103. The substrate 101 may detach from the base when the base is withdrawn from the receiving portion 203, so that the substrate 101 engages with the portion of the receiving portion 203 that defines the opening 202. Figure 9 shows an exemplary base, i.e., pin 301, in a withdrawal position for separating the base from the substrate 101 and polymer coating 102 to form a coated substrate having a tail portion 103. After the base is withdrawn from the substrate 101, the precursor 200 can be formed, and the tail portion 103 can be sealed to the polymer coating 102 and / or substrate 101 to seal the substrate and form a coated substrate. As shown in Figure 8, the precursor 200 may be repositioned so that the tail portion 103 of the precursor 200 faces a sealing system configured to seal the tail portion to the polymer coating 102 and / or substrate 101. In the example shown in Figure 8, the sealing system may include a heating device 404 for melting the polymer of the tail portion 103 to form a sealing area 104. The sealing system may also include rollers 403 for pressing the laminated tail portion 103. Next, a coated substrate 105, as shown in Figure 1, is manufactured, having a substrate 101 enclosed by a coating layer 102 and a distinct sealing area 104.

[0127] Figures 4 and 5 show an exemplary system 300 comprising a heating pin system 304. As shown, the receiving portion 203 may define a second cavity 305 for housing the heating pin system 304. After the substrate 101 is received in the cavity 203a of the receiving portion 203, the heating pin system 304 may be moved toward the substrate 101 relative to the receiving portion 203. The pins 301 may be heated by the heating element 302 to a desired temperature, for example, in the range of 50°C to 700°C. In one embodiment, the desired temperature of the pins 301 is higher than the melting point of the substrate 101. In another embodiment, the tip portion 301A of the pins 301 is higher than the melting point of the substrate in order to melt the surface of the substrate. The heated tip portion 301A of the pins 301 may contact the substrate 101 to cause the pins 301 to adhere to the substrate 101 by spot melting a small area of ​​the substrate 101. The pin 301 may be cooled to below the melting point of the substrate 101 in order to fix the substrate 101 to the pin 301 so that the pin 301 can be supported by the pin 301 alone, by embedding the tip 301A of the pin 301 into the substrate 101. In one embodiment, the heating element 302 may be configured to provide the pin 301 with energy selected from a range between 10 watts / square inch and 100 watts / square inch, depending on the melting temperature of the substrate 101. The pin 301 may be made of any available commercial grade stainless steel, copper, bronze, or other material with high thermal conductivity. The pin 301 may also be treated with a layer of non-stick coating such as PTFE or such material, and may have a sharp tip 301A at its distal end having a thickness / diameter generally smaller than the thickness / diameter of the pin 301. In one embodiment, the pin 301 may have a diameter in the range of 0.01 mm to 5 mm. The diameter of the pin 301 may be selected depending on the size and weight of the substrate. The selected pin diameter may be based on the weight of the substrate 101 and the minimum thickness of the coating layer 102 that can withstand tensile stress under vacuum. In one example, if the substrate diameter is 1 mm to 8 mm, pins with a diameter of 0.2 mm to 0.5 mm can be used. Other pin diameters are also envisioned in this disclosure.

[0128] Continuing the above example, the heating system 304 is housed in the cavity 305 and comprises a heating element 302 and an insulating material 303 to minimize heat loss and potential damage to other elements of the system 300. The pin 301 may be directly coupled to the heating element 302 and heated by the heating element 302. The heating element 302 may be connected to an external controller (not shown) that controls the temperature of the heating element. The heating system 304 may also be configured to move vertically along its longitudinal axis within the cavity 305 to move through the opening 202 without horizontal displacement or to be withdrawn from the opening 202. The substrate 101 fixed to the pin 301 may move away from the receiving portion 203 to provide a gap for the coating layer 102 to be wrapped around the substrate 101 and part of the pin 301. The coating equipment 401 may apply the coating layer 102 onto the substrate 101 and the raised edge 201 of the receiving portion 203, as shown in Figures 7 and 8. In one embodiment, the coating equipment 401 may be an extrusion coater, a slot die coater, a melt spray coater, a curtain coater, an electrostatic coater, a thermal film lamination coater, or an ultraviolet or electric beam curing coater. The coating equipment 401 may also be a thermoforming system, in which an improved thermoforming system heats the polymer film 102 in a suitable heating system to soften the polymer film so that it can be easily thermoformed, the suitable heating system may be a heated cylinder roll, a hot air blower heater, an infrared heating system, or other thermal heat source, and the softened film is then applied onto the substrate and the receiving part. The coating layer 102 may be pulled around the substrate 101 by vacuum suction through the opening 202 (shown by line A in Figure 8) or by pressing the coating layer 102 around the substrate 101 using an air pump (shown by line B in Figure 8). Applying vacuum or pneumatic pressure to the coating layer 102 may separate the coating layer 102 from the raised edge 201 of the receiving portion 203 in order to substantially enclose the substrate 101 and a portion of the base, such as the pin 301 shown in Figure 9.The heated pin system 304 can then be withdrawn from the cavity 203A by moving downward along its vertical axis to create a precursor 200. The precursor 200 may be transferred to another surface, for example, the roller surface 501A shown in Figure 16, to expose the tail portion 103. A heating device, for example, the heating device 404 shown in Figures 11 and 16, may melt the tail portion 103 to encapsulate the substrate 101, in which case the tail portion 103 melts and fuses with itself and / or the coating layer 102 to provide a sealing area 104 and create a coated substrate 105. A roller, for example, a cushion roller 403, may also be provided to press the tail portion 103 and laminate with itself and / or the coating layer 102 to produce a coated substrate 105 (Figures 1 and 12) having a substrate 101 encapsulated by the coating layer 102 and a distinct sealing spot 104.

[0129] Figure 17 shows one embodiment of the coating apparatus 401. As shown, the heating pin system 304 comprises pins 301 covered with an electrically insulating material, such as electrical tape, with the tip portion 301A remaining uncovered, and the heating pin system 304 is connected to a grounding station (not shown). The receiving portion 203 may be made of an electrically neutral material. Once the substrate 101 is held by the pins 301, it passes under the electrostatic coating or painting station 401A, and the coating composition may be sprayed onto the substrate 101, forming a coating layer 102 on the exposed surface of the substrate 101 and a portion of the pins 301. Any commercially available electrostatic coating material can be used. The coating layer 102 may be dried or cooled to form a precursor 200, depending on the properties of the polymer used (e.g., dry or solvent-based). The precursor 200 may then be treated with a heating apparatus and / or rollers as described above to produce a coated substrate 105.

[0130] Figures 13 and 14 show an example of a system 300 for manufacturing a coated substrate. As shown, the system 300 may comprise a plurality of receiving sections 203, each having a mating base, e.g., a pin 301. Each receiving section 203 may be positioned adjacent to one another to receive a substrate 101 into each receiving section. Figure 14 illustrates three receiving sections, but a plurality of receiving sections 203 may be provided. As described above, each receiving section has a mating base, e.g., a pin 301, that is movable relative to its mating receiving section 203. In the illustrated embodiment, each pin 301 may be coupled to a heating system 304, which includes a base 303a, a heating element 302, and an insulating material 303. The base 302a may be configured to move relative to the receiving section 203 to translate the pin 301 along its longitudinal axis through the respective openings 202 of the receiving section. The base material 101 may be fed into each of the multiple receiving portions 203 and coated by the system 300 as described above to provide a plurality of coated base materials 105.

[0131] Figures 15 and 16 show an exemplary apparatus 601 comprising a system 300 for manufacturing coated substrates. The apparatus 601 comprises the aforementioned system 300 incorporated into a rotating drum 501. More specifically, the system 300 is positioned around the surface of the rotating drum 501. A feed device 105, such as a vibrating feed device, feeds each of the plurality of substrates 101 to a plurality of receiving sections 203 positioned on the circumference of the drum 501. Each of the plurality of receiving sections 203 may receive the substrate 101 as it passes through the feed device 105. In the illustrated embodiment, the drum 501 may also comprise a vacuum box 204 for drawing vacuum through openings 202 of the receiving sections 203. Cavities 305 and 203A (better shown in Figure 3) are connected via openings 202 through which vacuum suction can be drawn. The vacuum pressure may be adjusted according to the thickness of the polymer film applied to each substrate 101 and the tensile behavior of the polymer under heat or plasticization. As each receiving section 203 rotates past the feed device 105, the vacuum box 204 may draw the substrate 101 into the receiving section. Each receiving section 203 may be spaced at a certain distance from one another on the circumferential surface of the drum 501, and each receiving section 203 has a corresponding base, for example, a pin 301 of a heating pin system 304 housed in a cavity 305 as shown in Figures 3, 4, and 5. The cavity 305 (better shown in Figures 3 and 5) houses the heating system 304 (better shown in Figure 4). As described above, the heating system 304 may spot melt on the surface of the substrate 101 using its tip 301A. The heating pin system 304 may be connected to an external control device (not shown) to control the temperature and timing of heating of the pins 301 and the movement of the pins relative to the receiving section 203.

[0132] The heating system 304 is configured such that the pin 301 moves through the opening 202 into the cavity 203A of the receiving portion 203 and translates along its longitudinal axis to engage with the surface of the substrate 101 so as to contact the tip 301A of the pin 301. The tip 301A may melt a small spot on the surface of the substrate 101 in order to embed the tip 301A into the substrate 101. After the tip 301A is embedded, the temperature at contact between the pin 301 and the substrate 101 decreases, and the area melted at the spot cools, bonding the tip 301A to the surface of the substrate 101. The pin 301 may raise the substrate 301 a certain distance from the receiving portion 203 to allow the application of a coating layer to substantially seal the substrate 101 and a portion of the pin 301. The drum 501 may rotate continuously to move the substrate 101 to a coating machine 401, such as a polymer film extruder, slot die coater, molten spray coater, curtain coater, electrostatic coater, thermal film lamination coater, or UV or electric beam curing coater, which are configured to apply a coating layer 102 to the receiving section 203 and the substrate within it. The coating layer 102 is vacuum-formed to create a precursor 200 by covering a substantial surface area of ​​the substrate 101 and a portion of the pin 301. The drum 501 may continue to rotate until the receiving section 203 is no longer in communication with the vacuum box 204. The pin 301 may be pulled out through the opening 202 to detach the precursor 200 from the pin 301. In one example, the pin 301 is pulled out when the precursor 200 is over the receiving section 203b of the drum 602, allowing the precursor 200 to fall into one of a plurality of receiving section 203b positions around the surface of the drum 602. The drum 501a may include a vacuum box 205 for holding the precursor 200 in a mating receiving portion 203b under vacuum. The sealing system 405 may include a heating device 404 configured to melt the tail portion 103 of the precursor 200 and fuse the polymer of the tail portion 103 to form a sealing region 104. The sealing system 405 may also include a roller 403 for laminating the tail portion 103.The coated substrate 105 can then be rotated to the collection device 206, where the receiving portion 203b is no longer in communication with the vacuum box 205, allowing the coated substrate 105 to be detached and transferred to the collection device 206.

[0133] Figures 18-23 show an exemplary system 700 for producing coated substrates described herein, e.g., precursor 200 and coated substrate 105. The system 700 may include a feeder (not shown) configured to feed the substrate 101 into a receiving portion 703, each receiving portion 703 having a mating base. As described above, the bases may have various designs. As shown in Figures 18-20, a base 709 defines a channel 712 within the base 709 that extends to a platform 720 configured to receive the substrate 101. The receiving portion 703 may have a width / diameter XX and depth YY configured to receive the substrate 101 and allow engagement between the base 709 and the substrate 101. An opening 722 may have a width / diameter ZZ configured to allow the base 709 to translate through the opening 722 while preventing the substrate 101 from passing through the opening 722. The width / diameter ZZ may also allow for clearance of the base 709 when partially coated by the coating layer 702. The diameter XX of the receiving portion 703 may generally be maintained at twice the diameter of the substrate 101. The feeding device can be any suitable device for delivering the substrate to the receiving portions 703 of the system 700. As described above, in one example, the feeding device may be a hopper and / or comprise a vibrating feeding device having aligned channels for feeding the substrate 101 to one or more receiving portions 703 of the system 700. The receiving portion 703 may define a cavity 703A for receiving the substrate 101. As shown in Figures 3 and 5, the receiving portion 703 may define an opening 722 having a region configured to receive and hold the substrate 101. Each base is movable relative to its mating receiving portion 703 through the opening 722, and each base is configured to have an extended position in which the base extends into its mating receiving portion to engage with the substrate on the base. In one example, the base is configured to translate along its longitudinal axis through the opening 722 of the mating receiving portion without horizontal displacement in order to engage with or disengage from the base material 101. In its extended position, the base 709 can receive the base material 101 on the platform 720.Vacuum pressure provides suction through channel 712, which can pull the substrate 101 to engage with and / or maintain engagement with platform 720. Channel 712 may have a width / diameter CC configured to provide suction force for securing the substrate 101 to platform 720. The receiving portion 703 may have raised edges 701 around the receiving portion 703 for receiving the coating layer. A first coating apparatus, e.g., a polymer film extruder 741, may be configured to apply the coating layer 702 to the receiving portion 703. As shown in Figure 20, the substrate 101 may be received by the receiving portion 703 before the application of the coating layer 702 to the receiving portion 203. The receiving portion 203 may receive the substrate 101 before extending the base 709 into the cavity 703A, or after the base 709 has been extended into the cavity 703A.

[0134] Figure 21 shows the system 700 after the coating layer 102 has been applied to the receiving portion 703 and the substrate 101. A biasing device may be provided which is configured to bias the polymer coating around the substrate and a portion of the base. In one example, the biasing device may be a vacuum pump configured to apply vacuum pressure (shown as line A in Figure 21) to pull the coating layer 702 around the substrate 101 and a portion of the base to form a precursor 200 shown in Figure 22. In one example, the vacuum suction airflow may be maintained between 20 cubic feet / min (CFM) and 200 CFM (ft3 / min) through the opening 722. In another example, the biasing device may also be an air pump configured to apply pressure (shown as line B in Figure 21) to bias the coating layer 702 around the substrate 101 and a portion of the base.

[0135] In embodiments shown in Figures 19-23, the system 700 comprises a receiving section 703 having a receiving section heating system 717 for heating the coating layer 702. As shown, the receiving section heating system 717 may be positioned on the edge 701 of the cavity 703A, and the heating system 717 may heat the molten coating layer 702 to separate it from the edge 701 under biasing from a biasing device. For example, the biasing device may vacuum the molten / softened film 702 through an opening 722 to wrap around a portion of the substrate 101 and the base 709. In one example, the receiving section heating system 717 may be a heating coil around the edge 701. In one example, the receiving section heating system 717 may maintain a temperature between 50°C and 300°C, or between 60°C and 200°C, or between 100°C and 200°C, depending on the molten properties of the coating layer 702.

[0136] Continuing the above example, once the coating layer 702 is wrapped around the substrate 101 and part of the base 709, the base can be withdrawn from the mating receiving portion 703, separating the base from the substrate 101 and the polymer coating 702 to form a coated substrate having a tail portion 703. The substrate 101 may be separated from the base when the base is withdrawn from the receiving portion 703, so that the substrate 101 engages with the portion defining the opening 722 of the receiving portion 703. Figure 23 shows an exemplary base in the withdrawn position separated from the substrate 101 and the polymer coating 102 to form a coated substrate having a tail portion 103. After the base is withdrawn from the substrate 101, a precursor 200 can be formed, and the tail portion 103 can be sealed to the polymer coating 102 and / or the substrate 101 to encapsulate the substrate and form a coated substrate. As described above with respect to Figure 8, the precursor 200 may be repositioned so that the tail portion 103 of the precursor 200 faces a sealing system configured to seal the tail portion to the polymer coating 102 and / or substrate 101 to form a coated substrate 105 having a sealing region 104.

[0137] As described above, the receiving portion and the mating base may have different dimensions depending on the base material. In one example, the base material 101 may be a tablet of NPK (15-15-15) fertilizer prepared via a commercially available tablet press (TDP-5) to provide a urea tablet having a diameter of 10 mm and a thickness of 8 mm. The receiving portions 203 and 703 may have the following dimensions: the width / diameter XX of the receiving portion is 25 mm, the depth YY is 20 mm, the width / diameter WW of the base is 5 mm, the width / diameter CC of the channel is 2 mm, the depth HH of the base from the bottom of the receiving portion is 18 mm, and the diameter ZZ of the opening of the receiving portion is 10 mm. A commercially available 25 μm polylactic acid (PLA) polymer film was used for coating. The film was heated with an overhead heater to soften it to a degree that allowed for thermoforming. Vacuum suction was then applied through the opening of the receiving part, and the PLA film coated the fertilizer tablet, covering a considerable surface area and forming a tubular excess film with a diameter of approximately 5 mm and a length of 8 mm. This excess film was heated via a heating device, and the excess film was welded to the coated layer and the uncoated fertilizer surface, so that the fertilizer tablet was sealed between the coated layer and the welded spots (i.e., the sealing area). This resulted in a completely coated substrate 105 (shown in Figure 1), and the average coating weight of the coated fertilizer tablet 105 was approximately 2% of the total weight of the coated tablet.

[0138] Figure 24 shows an exemplary apparatus 901 comprising a system 700 for manufacturing coated substrates. The apparatus 901 comprises the aforementioned system 700 incorporated into a rotating drum 901. More specifically, the system 700 is positioned around the surface of the rotating drum 901. A feed device 705, such as a vibrating feed device, feeds each of a plurality of substrates 101 to a plurality of receiving sections 703 positioned on the circumference of the drum 901. Each of the plurality of receiving sections 703 can receive the substrate 101 as it passes through the feed device 705. In the illustrated embodiment, the drum 901 may also include a vacuum box 904 for drawing in a vacuum through openings 722 in the receiving sections 703. The cavity 703A (better shown in Figure 18) and the vacuum box 904 are connected via openings 722 and channels 712 through which vacuum suction can be performed. The vacuum pressure can be adjusted depending on the thickness of the polymer film applied to each substrate 101 and the tensile behavior of the polymer under thermal or plasticization conditions. As each receiving section 703 rotates past the feed device 705, the vacuum box 904 can draw the substrate 101 into the receiving section. Each receiving section 703 may be at a certain distance from each other on the circumferential surface of the drum 901, and each receiving section 703 has a corresponding base, as shown in Figures 18-23. The vacuum pressure passing through the channel 712 can hold the substrate on the platform of the base 709 when the coating layer 102 is applied to the substrate 101.

[0139] The base 709 is configured to translate along its longitudinal axis through the opening 202 into the cavity 703A of the receiving portion 703 and engage with the substrate 101. The base 709 may raise the substrate 301 at a distance from the receiving portion 703 to allow the coating layer to be applied so as to substantially encapsulate the substrate 101 and a portion of the base 709. The drum 901 may rotate continuously to move the substrate 101 to receive polymer from a coating device 401 configured to apply the coating layer 102 to the receiving portion 703 and the substrate within it.

[0140] In one embodiment, the coating layer 702 may pass under a first film surface treatment station 730 where a surface treatment is performed on a first surface 702a of the coating layer 702, then the coating layer 702 may pass under a second surface treatment station 731 where a second surface treatment is performed on a second surface 702b of the coating layer 702, and then the coating layer 702 may pass under a third film surface treatment station 732 where further treatment may be performed. The film surface treatment stations are optional, and there may be more or fewer surface treatment stations depending on the requirements of the coated substrate 105. The surface treatment stations may be coating stations, heating stations, and / or humidifying stations.

[0141] Continuing the above example with respect to Figure 24, the coating layer 702 is vacuum-formed to cover a substantial surface area of ​​the substrate 101 and a portion of the base 709 that forms the precursor 200. The drum 901 may continue to rotate until the receiving portion 703 is no longer in communication with the vacuum box 904. The base 709 may be pulled out through the opening 722 to detach the precursor 200 from the base 709. In one example, the base 709 is pulled out when the precursor 200 is on the receiving portion 703b of the drum 902, allowing the precursor 200 to fall into one of a plurality of receiving portions 703b positioned around the surface of the drum 902. The drum 902 may include a vacuum box 905 for holding the precursor 200 in the opposing receiving portion 703b under vacuum. The sealing system 907 may include a heating device 904 configured to melt the tail portion 103 of the precursor 200 and fuse the polymer of the tail portion 103 to form a sealing region 104. The sealing system 907 may also include a roller 906 for stacking the tail portions 103. The coated substrate 105 may then be rotated to a collection device 706 in which the receiving portion 703b is no longer in communication with the vacuum box 905, allowing the coated substrate 105 to be detached and transferred to the collection device 706.

[0142] Figure 25 shows an exemplary apparatus 1000 comprising a system 700 for manufacturing coated substrates. Apparatus 1000 includes a double-plate conveyor belt system 1507 comprising a cavity plate 1200b and a platform plate 1200a, which are described in detail below. The apparatus may also include a polymer film unwinder 1508 for feeding a polymer film for the coating layer 102 into the plate system 1207. The polymer film for the coating layer 1 may pass under a heating system 1501 to heat-soften the film before it is applied to the receiving section 703 of the plate system 1207. Vacuum suction may be provided to the receiving section 703 of the plate system 1207 by a vacuum box 1505 through an opening 1205 and a channel 712 (shown in Figure 26 and described below). Vacuum suction may pull the coating layer 103C onto the base 709, as described later with reference to Figure 31. Excess polymer around the receiving portions 703 may be collected from the surface of the plate system 1207 by a film collection unit 1502. The film collection unit may include a scraper or a weak vacuum source for collecting residual film between the receiving portions 703. A feed device 1503, such as a vibrating feed device, feeds multiple substrates 101 into multiple receiving portions 703 of the plate system 1207, as will be described later with reference to Figure 33. The feed device may include multiple channels, each aligned with the opposing receiving portion 703, for feeding the substrates 101 into each receiving portion 703. A unwinder 1508 may provide the plate system 1207 with a polymer film for a coating layer 102-1, as will be described later with reference to Figure 33. The polymer film for the coating layer 102-1 may pass under a heating system 1504 to heat-soften the film before applying it to the substrates 101 and receiving portions 703 of the plate system 1207. As will be described later with reference to Figures 33-34, the vacuum box 1506 can pull the coating layer 102-1 around the substrate 101 by vacuum pressure and part of the base 709, thereby forming the precursor 200B shown in Figure 35.Next, the sealing system 1511 can heat-shrink or seal the overlapping tail portions 103 and the coating layer 103C to form the coated substrate 105B shown in Figure 36. The coated substrate 105B may then be collected in a collection system 510, for example, a container.

[0143] Figures 26 and 27 show exemplary platform plate 1200a and cavity plate 1200b, respectively. The cavity plate 1200b may have a plurality of receiving portions 703, which may be machined into the plate 1200b by, for example, a CNC machining system. The platform plate 1200a may have a base 709 for engaging with the substrate 101. The base 709 may have a top surface platform 1204 for engaging with the substrate 101. The top surface platform 1204 may have a channel 712 through which vacuum pressure can be drawn. The platform 1204 may have a generally recessed shape to hold the substrate 101. The base 709 may also have one or more vacuum suction holes 1205 positioned around the base 709 for pulling polymer films 102-1 and 103C toward the base 709 using vacuum pressure. In one example, the diameter of the platform 1204 is less than or equal to the diameter of the substrate 101. The platform plate 1200a is positioned beneath the cavity plate 1200b, which aligns each base plate 709 with the corresponding opening 202, so that the base plates 709 can translate through the openings between the extended positions shown in Figures 30 and 31.

[0144] Figure 28 shows a cross-sectional view of an exemplary platform plate 1200a. The platform plate 1200a includes at least one biasing member 1206, for example, a spring, to apply a biasing force to the cavity plate 1200b. In one embodiment, the biasing member is a cushion spring oriented perpendicular to the plate 1200a. The vacuum suction hole 1205 is shown by a dashed line to indicate the flow path of vacuum pressure through the plate 1200a. As shown, the vacuum suction hole may extend along a length exceeding 50% of the length of the base 709. In one embodiment, the vacuum suction hole may extend substantially to the platform 1204.

[0145] Figure 29 shows a cross-sectional view of an exemplary cavity plate 1200b. When the cavity plate 1200b is positioned on the platform plate 1200a, the base 709 may extend into the cavity 703a through the opening 202. The base 709 is configured to translate along its longitudinal axis into the cavity 703A of the receiving portion 703 through the opening 202 and engage with the substrate 101. As described above, the cavity 703A may be sized to receive the substrate 101 and may have a raised edge 701 around the receiving portion 703 to receive the coating layer. In the example shown in Figure 20, the substrate 101 may be received by the receiving portion 703 before the coating layer is applied to the receiving portion 703. In another example, the coating layer may be provided to the receiving portion 703 and / or base 709 before receiving the substrate 101. As described above, the receiving portion 703 can receive the base material 101 before the base 709 is extended into the cavity 703A, or after the base 709 has been extended into the cavity 703A.

[0146] Figure 30 shows a cross-sectional view of an exemplary cavity plate 1200b positioned on a platform plate 1200a. The cavity plate 1200b may be located on a biasing member 1206 that provides a biasing force to the cavity plate. The conveyor belt system 1507 may include actuators 2130 that move the cavity plate 1200b and the platform plate 1200a toward or toward each other. The actuators 2130 may include a surface positioned to bias the cavity plate 1200a toward the platform plate 1200b, overcoming the force of the biasing member 1206, as the conveyor belt system rotates the cavity plate 1200b and the platform plate 1200b to contact the surface. The base 709 extends into the cavity 703a through the opening 202. Together, the plate system 1207 comprises the cavity plate 1200b, the platform plate 1200a, and the base 709. Multiple overlapping cavity plates and platform plates (i.e., plate system 1207) can be joined together on a conveyor to form a continuous flat surface, as shown in Figure 25. The base 709 can move along its longitudinal axis related to the cavity plate 1200b through the opening 202 to its extended position when the cavity plate 1200b moves toward the platform plate 1200a against the biasing force applied by the biasing member 1206. The base 709 can move to its withdrawn position when the biasing force applied by the biasing member 1206 overcomes the opposing force applied to the cavity plate 1200b.

[0147] Figure 31 shows a cross-sectional view of an exemplary cavity plate 1200b positioned on a platform plate 1200a shown in Figure 30, which is coated with a polymer film of coating layer 103C. The coating layer 103C may be applied onto the base plate 709 before the substrate 101 is received by the base plate 709. The coating layer 103C comprises a polymer film which may be heat-softened by a heating element 1501. The coating layer 103C may then be formed around the base plate 709 by drawing the heat-softened coating layer 103C around the base plate 709 by vacuum suction through an opening 1205, for example, as shown in Figure 32. In another embodiment, the coating layer 103C comprises a molten polymer on a roller applied onto the base plate 709, which forms a layer on the base plate 709 when cooled. In another embodiment, the coating layer 103C may comprise multiple coating layers by applying a polymer film on top of a preceding polymer film layer to form a multilayer polymer film. In one example, the coating layer 103C comprises a co-extruded polymer film or a latex-coated film.

[0148] Figure 32 shows a cross-sectional view of an exemplary cavity plate 1200b positioned on the platform plate 1200a shown in Figure 30, after being partially coated with a coating layer. As shown, the coating layer 103c may cover the platform 1204 and have an excess portion 103c extending onto the radial surface of the base 709.

[0149] Figure 33 shows a cross-sectional view of an exemplary cavity plate 1200b positioned on the platform plate 1200a shown in Figure 30, after being partially coated with a coating layer and receiving a substrate. As shown, the substrate 101 is received on a base 709, for example, a platform 1204 that has been previously coated with a coating layer 103c. The coating layer 102-1 may be applied to the substrate as described above in this disclosure. In one example, a heating element 1504 may be used to heat-soften the coating layer 102-1 for thermoforming onto the substrate 101 and base 709. The surface temperature of the coating layer 102-1 may be maintained between 50°C and 200°C before application to the substrate. It is preferable that the surface temperature of the coating layer 102-1 does not damage the substrate 101. As described above, the coating layer 102-1 may comprise an excess amount of polymer film relative to the overlapping base 709. In the illustrated embodiment, the coating layer 102-1 has a tail portion 103 that overlaps with the excess portion 103C extending on the radial surface of the base 709, as shown in Figure 34.

[0150] Figure 34 shows a cross-sectional view of an exemplary cavity plate 1200b positioned on a platform plate 1200a shown in Figure 30, which has a precursor 200B positioned on a base. The base 709 can be moved to its withdrawal position to remove the precursor 200B from the base 709. As shown, the substrate 101 is sealed by coating layers 102-1, 103C. After the base 709 is withdrawn, the overlapping tail portion 103 and excess portion 103C may be sealed to the polymer coating 102-1 and / or the substrate 101. In one example, a sealing system 1511 may heat and melt the overlapping tail portion 103 and excess portion 103C to fuse them together, forming a sealed region 104B shown in Figure 36. As the excess portion 103C and tail portion 103 shrink due to heat, a coated substrate 105B is formed. The sealing system 1511 may also include rollers (not shown) for laminating the tail portion 103 and the excess portion 103C onto the coating layer 102-1.

[0151] Figure 35 shows a precursor 200B of the coated substrate. Precursor 200B is similar to the precursors shown in Figures 2A and 2B, except that the tail portion comprises a coating layer 103C including an excess portion 103C. As shown in Figure 35, the substrate 101 of precursor 200B is encapsulated by a polymer film. The exemplary coated substrate 105B shown in Figure 36 may be formed by thermally melting and disintegrating the tail portion 103 and excess portion 103C of the coating layer 102-1, forming a reinforcing coating layer 108 bonded to the sealing region 104B. As shown in Figure 36, the reinforcing coating layer 108 encapsulates a portion of the substrate 101 and has edges bonded to the coating layer 102-1 and the sealing region 104B.

[0152] Figure 37 shows an isometric view of an exemplary cavity plate of system 2000 for manufacturing coated substrates as described herein. Dashed lines indicate edges hidden from view, and solid lines indicate visible edges. Exemplary system 2000 has similar features to exemplary systems 300 and 700 described above. System 2000 may include a feed device (currently shown) configured to feed a substrate 101 into a receiving portion 2111 having a mating base 2121 (shown in Figure 38). Multiple receiving portions 2111 may be provided on the surface of the cavity plate 2118. The receiving portions 2111 may define a cavity 2111A for receiving the substrate 101. As shown in Figure 37, the receiving portions 2111 may be provided on the coating plate 2118. The receiving portion 2111 may define an opening 2117, and each base is movable relative to its mating receiving portion 2111 through the opening 2117, and each base is configured to have an extended position in which it extends into its mating receiving portion to engage with a substrate on the base. Each base 2121 has a withdrawn position in which it is withdrawn from the cavity 2111A. In one example, the base is configured to translate along its longitudinal axis through the opening 2117 of the mating receiving portion without horizontal displacement in order to engage with or disengage from the substrate 101. The receiving portion 2111 may have a rim 2112 around the receiving portion 2111 to receive a coating layer.

[0153] In one embodiment, the receiving portion 2111 includes one or more detachment members 2119. The detachment members 2119 are fixed to the receiving portion 2111 and can define the volume between each member through which the member 2121B of the base 2121 translates. As shown in Figures 40, 42, and 43, the detachment members 2119 can overlap with the opening 2117 through which the base member translates. When the precursor 200 or 200B is positioned on the base 2121 and the base 2121 moves from its withdrawal position, the detachment members 2119 push the tail portion 103 of the precursor 200, or the overlapping tail portion 103 and excess portion 103C of the precursor 200B, in a direction perpendicular to the movement of the base 2121, which can detach the precursor 200 or 200B from the base 2121.

[0154] In one embodiment, a cavity plate 2118 having one or more receiving portions 2111 may be formed to desired dimensions using industrial machining or milling tools such as computer numerical control (CNC) or vertical machining center (VMC) machines. The dimensions of the receiving portions 2111 can be based on the dimensions of the substrate used for coating. In one example, a substrate with a diameter of 3 mm may be provided with receiving portions having a diameter of 6 mm and a depth of 3 mm.

[0155] Continuing the above example, the substrate 101 may be provided to the receiving section 2111. In one embodiment, the substrate may be provided to each receiving section 2111 as illustrated in Figure 37. Each substrate may be drawn into the receiving section 2111 by vacuum pressure or by gravity. A coating layer 200 comprising a polymer film may then be applied onto the substrate 101. Next, the coating layer 200 is passed under a cutting tool 2145, for example, a rotary die cutter, and the tip 2149 of the cutting blade 2147 cuts the film 200 around the edge of the cavity 111 (shown in Figure 48) to provide a coating layer sufficient to seal the entire surface of the substrate 101. The coating layer 200 can be pulled to the surface and around the substrate 101 by vacuum suction through the opening 2117 of the receiving section 2111. Vacuuming coats a substantial surface area of ​​the substrate 101 with the coating layer 200 and causes the substrate 101 to wrap around a portion of the positioning base 2121, forming an excess film or tail portion 1202 (shown in Figure 49), i.e., a precursor 200. The coated substrate 100 with the tail portion 1202 is then separated from the base 2121 by pulling the base 2121 out of the receiving portion 2111.

[0156] Figure 38 shows an isometric view of an exemplary platform plate 2200 of system 2000. As shown, the platform plate 2200 comprises one or more bases 2121 and a plurality of members 2121B, each having a surface that defines a plane XYZ to form a platform 2121A for receiving a substrate 101. In one embodiment, the surface of each member 2121B for receiving the substrate 101 may be concave. Each member 2121B may be positioned parallel to each other in a triangular pattern when viewed from above. In one embodiment, the members 2121B of the base 2121 are spaced apart from the detachable member 2119 when viewed along the longitudinal axis of the member 2121B. As shown, each member 2121B is indicated by a pin. Although a triangular pattern is shown, many other patterns, such as a square pattern or a hexagonal pattern, may be used. The base 2121 and its members 2121B that form the platform 2121A may generally be positioned within the opening 2117. The base 2121 and platform 2121A may move along the longitudinal axis of the base 2121 through the opening 2117 of the cavity. In one embodiment, members 2121B of the base 2121 may move between and / or beyond the detachment members 2119. The movement of the base 2121 may be controlled by a controller, which may control the relative position of the base 2121 to the receiving portion 2111 using, for example, an actuator 2130. In one example, the base 2121 is positioned on a platform plate 2200 positioned below the cavity plate 2118, allowing one or more bases 2121 to translate through the opposing opening 2117 of the cavity plate 2118. As the cavity plate 2118 and the platform plate 2200 move relative to each other, each base 2121 may move to the extended position of the base within the receiving portion 2111 at the same time that the cavity plate 2118 and the platform plate 2200 move toward each other, or to the withdrawn position at the same time that the cavity plate 2118 and the platform plate 2200 move toward each other.The platform plate 2200 may define vacuum openings 2125 that are positioned approximately in the center of member 2121B, and each opening 2125 is configured to provide vacuum pressure from a vacuum pressure source to the receiving portion 2111.

[0157] Figure 39 shows an isometric view of the cavity plate 2118 overlapping the platform plate 2200. The base 2121 is in an extended position to receive the substrate 101. Each member 2121 of the base 2121 is positioned between the detachment members 2119. The cavity plate 2118 may be moved relative to the platform plate 2200 by any means, such as an actuator 2130, a biasing member 2206. The actuator 2130 may include a conveyor belt system (e.g., system 1507) having a surface positioned to bias the cavity plate 2118 toward the platform plate 2200, overcoming the force of the biasing member 2206, as the conveyor belt system rotates the cavity plate 2118 and the platform plate to contact the surface. The base 2121 extends into the cavity 2111A through the opening 2117. The base 2121 may move along its longitudinal axis relative to the cavity plate 2118 through the opening 2117 to its extended position when the cavity, for example, plate 2118, moves toward the platform plate 2200. The base 2121 may move to its withdrawn position when the base 2121 is withdrawn through the opening 2117, for example, when the cavity plate 2118 separates from the platform plate 2200, and vice versa.

[0158] Figure 40 is an exemplary top view of a receiving portion and a detaching member according to the present disclosure. As shown, the receiving portion 2111 defines an opening 2117 through which a base 2121 can be translated. Three detaching members 2119 are arranged to overlap the opening 2117, for example, as shown in Figure 40. The detaching members are made of metal, plastic, rubber, or any other suitable material. In one embodiment, the detaching members are made of a rubber material, such as silicone rubber, configured to operate at high temperatures.

[0159] Figure 41 shows an exemplary cross-sectional view of the receiving portion and base along line AA-AA in Figure 40. The detaching member 2121B has a surface that engages with the tail portion 103 of the precursor 200 or the overlapping tail portion 103C and excess portion 103C of the precursor 200B, and applies a vertical force as the predator 2121 is moved to its withdrawal position, detaching the precursor 200 or 200B from the base 2121.

[0160] Figure 42 shows a top view of another exemplary receiving and detaching member according to the present disclosure. As shown, the receiving portion 2111 defines an opening 2117 through which the base 2121 can translate. The detaching member 2119A is positioned to overlap the diameter of the opening 2117 and extend across it.

[0161] Figure 43 shows another exemplary receiving portion and base according to the present disclosure. As shown, the receiving portion 2111 defines an opening 2117 through which the base 2121 can translate. The detaching member 2119B is positioned to overlap a portion of the opening 2117 and extend across it.

[0162] Figure 44 shows a cross-sectional view of the platform plate 2200 of Figure 38, having a member 2121B of a base 2121 positioned around an opening 2125 defined by the plate 2200. A biasing member 2206, such as a spring, may apply a biasing force to the cavity plate 2118 to move the base 2121 to the pulled-out position.

[0163] Figure 45 shows a cross-sectional view of a portion of the cavity plate 2118 that overlaps the platform plate 2200 shown in Figure 39. The base member 2121B of the base 2121 is in an extended position, as shown in Figure 46, with member 2121B extending between the detachment members 2119 through the opening 2117 and receiving the base material 101 on the base 2121A. The biasing member 2206 may be in a first position where the biasing force of the biasing member 2206 is less than the force compressing the platform plate 2200 and the cavity plate 2118 together. The openings 2117 and 2125 may be aligned so that a vacuum pressure source (not shown) can draw a vacuum through the aligned openings.

[0164] Figure 47 shows a cross-sectional view of a portion of the cavity plate 2118 that overlaps the platform plate 2200 shown in Figure 39, which has a substrate 101 mounted on a base 2121 coated with a coating layer 102. The coating layer 102 may be applied to the substrate 101 by coating equipment, such as a polymer film extruder, as described herein.

[0165] Figure 48 shows a partial cross-sectional view of a cavity plate 2118 that overlaps with the platform plate 2200 shown in Figures 45 and 47, which has a base plate 101 mounted on a base plate 2121 coated with a coating layer 102, and a cutting tool 2145. The cutting tool 2145 may be a rotary die cutter tool configured to cut a desired shape from the coating layer 102. In one example, the cutting tool 2145 may have dimensions that coincide with the perimeter of a receiving portion 2111. The receiving portion may have a surface 2701 around the receiving portion 2111 for receiving the coating layer 102. The cutting tool 2145 may be part of a conveyor belt system or roller where the tip 2149 of a cutting blade 2147 is positioned to cut the coating layer 102 at the surface 2701 of the receiving portion 2111. Although the cutting tool 2145 is indicated to cut the coating layer 102 on the opposite side of the receiving portion 2111, the cutting tool 2145 cuts the coating layer 102 around or adjacent to the receiving portion 2111 on the surface 2701. The tip portion 2149 can press the coating layer 102 against the surface 2701 and cut out the shape from the coating layer 200 to match the shape of the receiving portion 2111. Vacuum suction through openings 2117 and 2125 can pull the coating layer 200 around the substrate 101 and wrap around the substrate 100 and a portion of the member 2121B of the base 2121. In one embodiment, the cutting tool 2145 has a grid of cutting blades that match the shape of each receiving portion 2111 arranged in a grid pattern. As an example, the hexagonal receiving portion 2111 of the plate 2118 may have a hexagonal position of the blade on the surface of the cutting tool 2145, for example, the surface of a rotary die cutter, with the tip portion 2149 facing the surface 2701 of the receiving portion 2111.

[0166] Figure 49 shows a partial cross-sectional view of a cavity plate 2118 that overlaps the platform plate 2200 shown in Figures 45 and 48, having a precursor 200 provided on the base 2121. As described herein, the precursor 200 may be formed on the base 2121 by vacuum suction of a coating layer 102 around a portion of the substrate 101 and the base 2121. The tail portion 103 of the precursor 200 engages with the base 200 around a portion of the base 2121. The precursor 200 may be detached from the base 2121 by moving the base from an extended position to a withdrawn position.

[0167] Figure 50 shows a cross-sectional view of a portion of the cavity plate 2118 that overlaps the platform plate 2200 shown in Figure 47, which has a precursor 200 separated from the base 2121. The precursor 200 can be separated from the base 2121 by moving the base 2121 from its extended position to its withdrawn position shown in Figure 50. As the base 2121 translates through the opening 2117 between the detachment members 2119, the precursor 200 moves toward the detachment members 2119 along the longitudinal axis of the base 2121. When the tail portion 103 abuts against the detachment members 2119, the precursor 200 can be separated from the base 200 as the base 2121 moves through the opening 2117. The detachment members 2119 may collapse at least a portion of the tail portion 103. Once detached from the base 2121, the tail portion 103 of the precursor 200 may be thermally melted to form a sealing region 104 and create a coated substrate 105.

[0168] Figure 51 is a perspective break view of an exemplary tail portion of the precursor 200 shown in Figure 2A. As described herein, the exemplary tail portion 202A is a continuous extension of the coating layer 102 and may extend at any angle, for example, approximately perpendicular to the surface of the substrate 101 and away from the surface of the substrate 101. The tail portion 202A has a generally cruciate cross section, which may be formed by a four-member base by positioning four members 2121B at four right-angled vertices formed by four cruciate arms. Systems and methods described herein with respect to Figures 37-50 may be used to make a precursor 200 having the tail portion 202A in this manner.

[0169] Figure 52 is a perspective break view of an exemplary tail portion of the precursor 200 shown in Figure 2A. As described herein, the exemplary tail portion 202B is a continuous extension of the coating layer 102 and may extend at any angle, for example, approximately perpendicular to the surface of the substrate 101 and away from the surface of the substrate 101. The tail portion 202B has a generally triangular cross-section which can be formed by a three-member base by orienting three members 2121B at the three vertices of a triangle. Systems and methods described herein with respect to Figures 37-50 may be used to make a precursor 200 having the tail portion 202B in this manner.

[0170] Figure 53 is a perspective break view of an exemplary tail portion of the precursor 200 shown in Figure 2A. As described herein, the exemplary tail portion 202C is a continuous extension of the coating layer 102 and may extend at any angle, for example, approximately perpendicular to the surface of the substrate 101 and away from the surface of the substrate 101. The tail portion 202C has a generally cylindrical cross-section which can be formed by oriented a plurality of members 2121B in a circular pattern. In another example, a base of a single member may be used. The systems and methods described herein with respect to Figures 37-50 may be used to make a precursor 200 having the tail portion 202B in this manner.

[0171] Figure 54 is a fragmentary diagram of an exemplary sealing region of the coated substrate shown in Figure 1. As shown, the exemplary sealing region 104 may have a generally cross-shaped sealing spot 217A. The cross-shaped sealing spot 217A may be formed when external heat is applied to the tail portion 202A shown in Figure 51, causing it to melt and fuse.

[0172] Figure 55 is a fragmentary diagram of an exemplary sealing region of the coated substrate shown in Figure 1. As shown, the exemplary sealing region 104 may have a generally Y-shaped sealing spot 217B. The Y-shaped sealing spot 217B may be formed when external heat is applied to the tail portion 202B shown in Figure 52, causing it to melt and fuse.

[0173] Figure 56 is a fragmentary diagram of an exemplary sealing region of the coated substrate shown in Figure 1. As shown, the exemplary sealing region 104 may have a generally circular sealing spot 217C. The circular sealing spot 217C may be formed when external heat is applied to the tail portion 202C shown in Figure 53, causing it to melt and fuse.

[0174] The seal spots 217A, 217B, and 217C may have different properties from portion 102A of the coating layer 102, and may have a higher density and / or higher coating thickness than the main portion 102A of the coated substrate 105. The seal spots may appear as a single region on the surface of the coated substrate 105 that is distinctly different from the main portion 102A, and may appear only on one hemisphere of the coated substrate 105. Under a microscope, the seal spots may appear as distinct protrusions compared to the relatively smooth coating layer of the main portion 102A.

[0175] By repeating the method described herein, multiple coating layers 102 can be applied to a single substrate. When multiple coating layers are applied to the same substrate, the coated substrate will have the same number of sealing areas as the number of times the coating has been applied.

[0176] Referring to the method flowchart in Figure 57, several embodiments may provide a method for manufacturing a coated substrate.

[0177] In 3100, the substrate can be fixed to a base. The substrate can be fed into a receiving portion that defines an opening into which the cavity and base extend. The base may extend into the cavity to bond with the substrate, and the base translates along its longitudinal axis without horizontal displacement. The substrate may be a solid core. In another example, the substrate may be a fertilizer, a pesticide, a combination product of fertilizer and pesticide, a pharmaceutical tablet, a nutritional supplement tablet, an agricultural seed, a solid food article, or a water-soluble solid core. In one embodiment, the base includes a channel configured to provide vacuum suction for fixing the substrate to the base. In another embodiment, the base may be a pin that may be heated. The pin may be heated to a temperature higher than the melting point of the substrate; the substrate is fixed to the pin by bringing the pin into contact with the substrate and embedding a portion of the pin into the substrate.

[0178] At 3200, the first coating layer may be applied to the substrate. In one embodiment, the second coating layer may be applied to the base to partially coat the base before fixing the substrate to the base; and the substrate is delivered to the partially coated base. The second coating layer may be heated to thermoform the second coating layer around the base. In another embodiment, the edge of the first coating layer may be applied to the lateral surface around the cavity; and the edge of the first coating layer is cut off from the lateral portion of the cavity.

[0179] In 3300, the first coating layer may be wrapped around the substrate to substantially coat the substrate, and the first coating layer has excess coating of the first coating layer that extends around the base away from the substantially coated substrate. In one embodiment, the first coating layer may be wrapped around the substrate, which includes sucking the first coating layer around the substrate. In another embodiment, wrapping the first coating layer around the substrate includes blowing air along the periphery of the first coating layer. In another embodiment, an adhesive may be applied to the base to transfer the adhesive to the first or second coating layer that partially coats the base. Once sealed, the excess coating of the first coating layer with the adhesive may be pressed against itself, and the adhesive adheres the excess coating to the substrate.

[0180] At 3400, the base may be separated from the base material.

[0181] At 3500, a tail portion may be formed from the excess coating of the first coating layer, and the tail portion extends at an angle from the surface of the substrate. In one embodiment, the tail portion is formed from the excess coating of the first coating layer and a portion of the second coating layer.

[0182] In 3600, the tail portion may be sealed to the first coating layer to enclose the substrate. In one embodiment, the tail portion may be melted and laminated to the first coating layer.

[0183] Additional non-exclusive exemplary materials

[0184] The non-exclusive exemplary seeds as base material 101 may include seeds of various cultivated plants that can be classified as either monocots or dicots. Cultivated plants include, but are not limited to, the following: Cereals such as wheat, rye, barley, rye wheat, oats or rice; beets, such as sugar beets or fodder beets; fruits such as pears, stone fruits or soft fruits, such as apples, pears, plums, peaches, almonds, cherries, strawberries, raspberries, blackberries or gooseberries; legumes such as lentils, peas, alfalfa or soybeans; oil plants such as rapeseed, rapeseed / canola, mustard, olives, sunflowers, coconuts, cocoa beans, castor oil, oil palm, cracked nuts or soybeans; cucurbits such as pumpkins, cucumbers or melons; fiber plants such as cotton, flax, hemp or jute; citrus fruits such as oranges, lemons, grapefruit or mandarins; spinach, lettuce, asparagus Vegetables such as cabbage, carrots, onions, tomatoes, potatoes, cucurbits or bell peppers; cinnamon plants such as avocados, cinnamon or camphor; energy and raw material plants such as corn, soybeans, rapeseed, sugarcane or oil palm; corn; tobacco; nuts; coffee; tea; bananas; grapevines (table grapes and grape juice vines); hops; turf; natural rubber plants, or ornamental and forestry plants such as flowers, shrubs, broad-leaved trees or evergreen trees, for example, conifers; preferably grains such as corn, sunflowers, wheat, rye, barley, rye wheat, oats or rice; soybeans, cotton, rapeseed / canola, more preferably grains such as corn, sunflowers, soybeans, wheat, rye, barley, rye wheat, oats or rice.

[0185] Non-limiting exemplary fertilizers as base material 101 may contain fertilizer components for supplying nutrients to cultivated crops, such as nitrogen, phosphorus, potassium, silicon, magnesium, calcium, manganese, boron, and iron. Typical examples include nitrogen fertilizers such as urea, ammonium nitrate, magnesium ammonium nitrate, ammonium chloride, ammonium sulfate, ammonium phosphate, sodium nitrate, calcium nitrate, potassium nitrate, calcium cyanamide, urea (UF), crotonylidenediurea (CDU), isobutylidenediurea (IBDU), and granylurea (GU); phosphate fertilizers such as calcium superphosphate, corn superphosphate, molten phosphate, humic acid phosphate, calcined phosphate, calcined corn phosphate, magnesium superphosphate, ammonium polyphosphate, potassium metaphosphate, calcium metaphosphate, magnesium phosphate, ammonium sulfate phosphate, potassium ammonium nitrate phosphate, and ammonium chloride phosphate; potassium fertilizers such as potassium chloride, potassium sulfate, sodium potassium sulfate, potassium magnesia sulfate, potassium bicarbonate, and potassium phosphate; silicate fertilizers such as calcium silicate; magnesium fertilizers such as magnesium sulfate and magnesium chloride; calcium fertilizers such as calcium oxide, calcium hydroxide, and calcium carbonate; manganese fertilizers such as manganese sulfate, manganese magnesia sulfate, and manganese lag; boron fertilizers such as boric acid and borates; and iron fertilizers.

[0186] Non-limiting examples of polymer films may include non-enteric polymers: commercial-grade polymers used in pharmaceutical manufacturing, such as hypromellose, hydroxyethylcellulose, hydroxyethylmethylcellulose, sodium carboxymethylcellulose, hydroxypropylcellulose, polyethylene glycol, and ethylcellulose. Polymers for enteric coatings may include hypromellose phthalate, polyvinyl acetate phthalate, cellulose acetate phthalate, polymethacrylate, and shellac.

[0187] A polymer film in which PGA is dispersed in a matrix may be used. This polymer film may release PGA due to film degradation or when PGA elutes from the film matrix upon contact with a liquid medium or water. The rate of PGA release is controlled by the biodegradation rate and the rate of PGA elution from the matrix of the polymer film. Polymer films with different biodegradation rates may have different PGA release rates, and water solubility or miscibility of PGA, and the miscibility of PGA with the polymer, also affect the rate of PGA release from the film matrix. In some embodiments, PGA is applied together with a surfactant that facilitates the release of PGA from the film matrix.

[0188] Non-limiting exemplary PGAs for coating layers include fungicides, bactericidal agents, insecticides, nematicides, fungicides, microorganisms, microbial inoculants, rodenticides, herbicides, attractants, repellents, plant growth regulators, nutrients, plant hormones, minerals, plant extracts, acaricides or mite killers, molluscicides, germination promoters, pheromones, biological agents, biopharmaceuticals, tagants, etc.

[0189] Other non-limiting exemplary PGAs for coating layers are commercially available fluid concentrates. Flor concentrates may be spray-coated / roll-coated onto the surface of polymer films. Non-limiting examples of commercially available fluid concentrates include: imidacloprid-48%FS (also available from Bayer as Gaucho®), thiomethoxam-30%FS, thyram-40%FS, and thiophanate-methyl + pyroclothribine 50%FS. Many fluid concentrates are commercially available, and custom and customized formulations can also be prepared by blending various compatible concentrates in ratios suitable for the appropriate amount of active ingredient delivered to the seeds. Emulsion seed (ES) treatments are commercially available as oil-in-water emulsions of plant growth agents (PGAs). These PGAs can also be applied to the surface of films by either spray or roll coating. An example of a commercially available ES is metalaxyl-M-31.8%ES. Numerous ES treatment agents using different PGAs for seed application are commercially available and can be used for coating film surfaces. In one embodiment, the PGA is in liquid form together with the coating polymer. The plant enhancer may be dispersed in the polymer solution, solubilized in the polymer solution, or both. The solid content of the solution may be between 1% w / v and 60% w / v. This solution can be converted into a polymer film using any commercial means. The polymer and PGA in the solution may have a higher evaporation temperature if temperature-sensitive PGA is not required in the polymer film. If temperature-sensitive PGA is required, a solution with a lower evaporation temperature may be used, and the polymer solution and temperature may be adjusted to minimize or avoid temperature-induced degradation or death of the active ingredient.

[0190] In one embodiment, the methods, systems, and polymer films used in the coated substrates described herein may be manufactured with PGA dispersed in the film structure. The amount of PGA may be between 1% and 50% of the dry film weight. Temperature-sensitive PGA may be blended with a low-melting-point polymer such as polycaprolactone (available in trade name CAPA series melt-extruded grade resins). The PGA-filled film may be extruded onto a PVOH film to form a two-layer film, or it may be heat-laminated onto a PVOH film. PGEA is a Plant Growth Enhancing Agent, and in this specification, the term is used for individual agents or mixtures of different agents.

[0191] In one embodiment, the polymer film used in the methods, systems, and coated substrates described herein may be manufactured with PGA dispersed within the film structure. The amount of PGA may be between 1% and 50% of the dry film weight. Temperature-sensitive PGA may be blended with a low-melting-point polymer such as polycaprolactone (available in trade name CAPA series melt-extruded grade resins). The PGA-filled film may be extruded onto the seed surface or heat-laminated at a temperature low enough not to damage the seed. The PGA-filled film covers the seed surface to between 10% and 90%, preferably 30% and 70%, and more preferably 60% and 70%. The PGA is released slowly through the film structure as the film degrades, or through elution from the film.

[0192] Polymer films containing water-soluble films, which may also contain PGA, can be prepared by known solvent casting methods, in which a polymer solution or aqueous dispersion is poured onto a smooth metal surface and the water or solvent is evaporated, leaving a smooth thin film. Casting is a well-known process in the water-soluble film manufacturing industry. Solvent-cast films can be prepared using commercially available slot-die coating processes (slot-die coating equipment is available from Nordson Inc.).

[0193] Other non-limiting exemplary PGAs for coating layers include dry mixtures containing different PGAs.

[0194] In one embodiment, the methods, systems, and polymer films used in the coated substrates herein may comprise a coating composition comprising a dry mixture in particulate form, wherein the individual components are blended into the dry mixture, either in powder form or in the form of composite particles comprising multiple components. The dry coating composition can be applied to the surface of the film via electrostatic powder coating.

[0195] Microcapsule suspensions of seed treatment PGAs such as FORCE ST from SYNGENTA can also be applied as a coating to the film surface. Dry or wettable powders (WP) of seed treatment PGAs are also commercially available. The WP may be dry-coated on the film surface or embedded in the film structure on one side of the film. Non-limiting examples include carbendazim-25%DS, tebuconazole-2.5%DS, carbosulfan-25%DS, and carboxyne-37.5+thyram-37.5%DS.

[0196] The coating layer according to this disclosure may contain a suitable bactericide. Non-limiting examples of suitable bactericides include, for example, strobilurin bactericides, azole bactericides, conazole bactericides, triazole bactericides, amide bactericides, benzothiadiazole bactericides, or combinations thereof. In other embodiments, the bactericide may include azoxystrobin, metminostrobin, orysastrobin, paclobutrazol, acibenzol-S-methyl, chlorothalonil, mandipropamide, thiabendazole, chlorothalonil, triadimenol, cyprodinil, penconazole, boscalid, bixafen, fluopyram, fenpropidine, fraxapyroxad, penflufen, fluoxastrobin, benthenavalicarb, benthenavalicarb isopropyl, dimethomorph, flusulfamide, thiophanate-methyl, triticonazole, flutriafole, cyram, carboxyne, carbendazim, or combinations thereof. Typical fungicides include captan (N-trichloromethyl)thio-4-cyclohexane-1,2-dicarboximide), thyram (tetramethylthioperoxydicarbondiamide; marketed under the trade name Proceed), metalaxyl (methyl N-(2,6-dimethylphenyl)-N-(methoxyacetyl)-DL-alaniic acid), and fludioxonil (4-(2,2-difluoro-1,3-benzodioxol-4-yl)-1-H-pyrrole-3-carbonitrile; blended with mephonoxam). Examples include iodine (marketed under the trade name Maxim XL), difenoconazole (marketed under the trade name Dividend 3FS), carbendadium iprodione (marketed under the trade name Rovral®), ipconazole, mephonoxam (marketed under the trade name Apron XL), tebuconazole, carboxyne, thiabendazole, azoxystrobin, prochloraz, and oxazixyl (N-(2,6-dimethylphenyl)-2-methoxy-N-(2-oxo-3-oxazolidinyl)acetamide). The fungicide may be included in the seed coating composition of the present invention in an amount of 0.0001 to 10% by weight, based on the total weight of the coated seeds.

[0197] The coating layer according to this disclosure may also contain a suitable nematicidal agent. Non-limiting exemplary nematicidal agents may include avermectin nematicidals, carbamate nematicidals, and organophosphate nematicidals, benomyl, benkrothiaz, and combinations thereof. Nematicidal agents may also include nematically active organisms such as bacteria and fungi. For example, Bacillus firmus, Bacillus cereus, Bacillus spp, Pasteuha spp, Pochonia chlamydosporia, Pochonia spp, and Streptomyces spp. An example of a ready-to-use nematicidal agent is AVCTA® from Syngenta.

[0198] The coating layer according to this disclosure may also contain a suitable insecticide. Non-limiting exemplary insecticides include pyrethroids, organophosphates, caramoyl oximes, pyrazoles, amidines, halogenated hydrocarbons, neonicotinoids, and carbamates and their derivatives. Particularly preferred classes of insecticides include organophosphates, phenylpyrazoles, and pyretoids. Preferred insecticides are those known as terbuphos, chlorpyriphos, fipronil, chlorethoxyphos, tefluthrin, carbofuran, imidacloprid, and tebupyrimphos. Commercially available insecticides include imidacloprid (commercially traded as Gaucho®), clothianidin (commercially traded as Poncho® by Bayer), thiomethoxam (commercially traded as Cruiser® by Syngenta), and fipronil (commercially traded as Regent® by BASF). The insecticide may be included in the seed coating composition of the present invention in an amount of 0.001% to 10% by weight, based on the total weight of the coated seeds.

[0199] A mixture of insecticides and fungicides as PGA in the coating composition can also be used in the present invention. Some examples of drug mixtures are: clothianidin / methconazole; neonicotinoid / ethaboxam; neonicotinoid / 2-[2-(2,5-dimethylphenoxymethyl)phenyl]-2-methoxy-N-methylacetamide; neonicotinoid / torukurophosmethyl; metconazole / ethaboxam; 8 These are metconazole / 2-[2-(2,5-dimethylphenoxymethyl)phenyl]-2-methoxy-N-methylacetamide; etaboxam / 2-[2-(2,5-dimethylphenoxymethyl)phenyl]-2-methoxy-Nmethylacetamide; etaboxam / torukurophosmethyl; 2-[2-(2,5-dimethylphenoxymethyl)phenyl]-2-methoxy-N-methylacetamide / torukurophosmethyl; 2-[2-(2,5-dimethylphenoxymethyl)phenyl]-2-methoxy-N-methylacetamide / metalaxyl; 2-[2-(2,5-dimethylphenoxymethyl)phenyl]-2-methoxy-N-methylacetamide / mephenoxam; and 2-[2-(2,5-dimethylphenoxymethyl)phenyl]-2-methoxy-N-methylacetamide / ipconazole.

[0200] The coating layer according to this disclosure may also contain herbicides as PGA. Non-limiting exemplary herbicides include triazine herbicides such as aryloxycarboxylic acid, aryloxyphenoxypropionate, cyclohexanedione oxime, hydroxybenzonitrile, sulfonylurea, triazolopyrimidine, trikethion, metrivudine, hexaxinone or atrazine; sulfonylurea herbicides such as chlorsulfuron; uracil herbicides such as renacil, bromacil or tarbacil; urea herbicides such as linulon, diuron, siduron or nevlon; acetanilide herbicides such as alachlor or metrachlor; and thiocarbamate herbicides such as benthiocarb or trialate. This includes oxadiazolon herbicides such as oxadiazone; isoxazolidone herbicides, phenoxyacetic acid; diphenyl ether herbicides such as fluadifop, acyfluorphene, bifenox, or oxyfluorphene; dinitroaniline herbicides such as trifluralin; organophosphonate herbicides such as glufosinate salts and esters, glyphosate salts and esters; and / or dihalobenzonitrile herbicides such as bromoxynil or ioxinil, benzoic acid herbicides, dipyridyl herbicides such as paraquat; and other herbicides such as chromazon, carfentrazone, saflufenacil, and pyroxasulfone.

[0201] The coating layer according to this disclosure may also contain plant growth regulators. Non-limiting exemplary plant growth regulators include potassium azide, 2-amino-4-chloro-6-methylpyrimidine, N-(3,5-dichlorophenyl)succinimide, 3-amino-1,2,4-triazole, 2-chloro-6-(trichloromethyl)pyridine, sulfathiazole, dicyandiamide, thiourea, guanylthiourea, or combinations thereof.

[0202] The coating layer according to this disclosure may also contain microorganisms. Non-limiting exemplary microorganisms include any bacteria, fungi, or viruses that have any beneficial effect in agriculture, such as controlling weeds, pests, or diseases, or improving plant growth, emergence, or yield. Some non-limiting examples of bacteria that may be used include members of the genera Pseudomonas (e.g., P. fluorescein), Bradyrhizohium (e.g., B. japanicum), Serratia, Arthrobacter, Azospirillum, Rhizobiurn, and Bacillus.

[0203] For water-soluble or hydrophilic films, it has been observed that moisture acts as a plasticizer, and when water is lightly sprayed onto the film, the film structure softens, making the film flexible and facilitating vacuum forming. According to an embodiment of the present invention, a 20-micron thick water-soluble PVOH film 102 passes under a film processing station 306, where moisture is sprayed onto the film 102, with the amount of moisture applied being balanced so as not to damage the integrity of the film structure, and the application of moisture makes the film 102 flexible, after which the film 102 is applied onto a solid core 101 in a housing cavity 805, and under vacuum, the film 102 is vacuum-formed around the surface of the core, covering a considerable surface area of ​​the core 101 with a layer of film 102, thus forming a polymer film-coated core 106.

[0204] In another embodiment of the present invention, the polymer film 102 is a water-soluble 20-micron PVOH film, and the film 102 is applied to the surface 102a using a commercially available wax-based release agent at a spray coating station 308. The coating composition is ready-to-use Poncho® 1250 from BASF, and the seeds 101 are corn seeds. The coating composition 109 is applied to the film 102 so that each seed receives 1.28 mg (average value) of the active ingredient. The coating composition (Poncho® 1250) is applied via a roll coater 306, the PVOH film absorbs moisture from the coating composition, the coating composition adheres to the surface 102b of the film 102, the coated film 102 is then fed onto the seeds so that the seeds are coated with the coated film 102, the seeds are then passed under an air dryer where most of the moisture absorbed by the film 102 evaporates, and the coated seeds produced here comprise the seed, the film coating layer 102 having a coating of a seed treatment agent on its surface 102b, and an anti-stick / seed flowability enhancer coated on the surface 102a. The polymer coated seeds 106 produced here have PGA sandwiched between the surface of the seed 101 and the surface 102b of the polymer film 102, so the film coated seeds produced here are dust-free and free-flowing.

[0205] According to one embodiment of this specification, the seed flow improver coated on the surface 102a of the polymer film 102 is a product from BASF's Flo Rite® series, more specifically Flo Rite® 1706.

[0206] In one embodiment of the present invention, a solid core 101 is completely coated with two separate polymer films, one of which is cold water soluble, the first polymer film 102 covering a first portion of the surface area of ​​the solid core 101, the second polymer film 102a covering a second portion of the surface area, and the second polymer film 202 covering the surface area not covered by the first polymer film 102. The first polymer film 102 may be prepared by applying a coating composition to surface 102b and a flow improver to surface 102a, and the second polymer film 102a may be prepared similarly. The coating composition applied to the underside of the first polymer 102 and the coating composition applied to the second polymer film 202 may be similar or different. The coating can be carried out using the processes described in U.S. Patent Application Publication 2015 / 0218059 A1 and U.S. Patent Application Publication 2018 / 0214834 A1, the information of which is incorporated herein by reference.

[0207] According to one embodiment of this specification, a microbial inoculant is applied to the surface of a film 102, and the inoculant is adhered to the surface 102b. Adhesion of a commercially available dry inoculant can be achieved by first applying a thin layer of adhesive to the surface 102b of the film at a processing station 309, and then applying the inoculant onto the adhesive layer at a processing station 306, where the processing station 306 may be a roller coater in which the dry particulate form of the inoculant is present and rollers transfer the dry inoculant onto the adhesive layer. An alternative method of applying the inoculant to the film may be by pressing the dry inoculant onto the softened surface of the film 102, where the processing station 309 applies a mist of moisture to soften the film.

[0208] In one embodiment of the present invention, PGA may be applied by electrostatic deposition, where processing station 309 is a corona discharge or plasma processing station, the surface 102b of film 102 is charged, and then charged dry PGA particles are applied to the charged surface of the film at processing station 306, where the dry PGA particles adhere to the surface 102b under electrostatic attraction, and then film 102 is coated onto a solid core 101, creating a coated core 106 having dry PGA beneath film 102, where the dry PGA is sandwiched between the surface of core 101 and the surface 102b of film 102.

[0209] The inoculant is adsorbed onto a carrier, and the carrier of the inoculant is preferably peat material. Alternatively, vermiculite, clay, silt, graphite, talc, filtered sludge, coy dust, bagasse, composted corn cobs, or coal dust may be used.

[0210] In one embodiment of the present invention, a dry inoculant in a carrier is applied to a film via electrostatic coating. The film surface 102a is charged using a corona-charging wire that causes a negative change on the surface of the film 102, charging the inoculant and causing a positive change on the surface of the inoculant particles. The charged dry inoculant moves to the film, and the dry inoculant particles adhere to the surface of the film 102. The amount of dry inoculant applied may be in the range of 0.5% to 5% of the seed weight.

[0211] In one embodiment of the present invention, microorganisms are incorporated into a sodium alginate matrix, and this sodium alginate film is attached to the surface of the seed along with the application of film 102. In another embodiment of the present invention, the sodium alginate matrix having passivated microorganisms may be pulverized into a powder with a particle size of less than 50 microns, and this powder is then attached to the surface of the seed using an adhesive. In another embodiment of the present invention, the inoculant is prepared as microcapsules in alginate, these microcapsules are attached to the surface of the seed, and the seed is coated with film 102.

[0212] In one embodiment of the present invention, a powdered inoculant is applied to seeds, and then a polymer layer is applied to the inoculant-coated seeds, with the polymer film protecting the dry inoculant from the environment until the seeds germinate. The inoculant powder may be a commercially available microbial inoculant, and the polymer film may be a water-soluble polymer film such as PVOH or a water-insoluble biodegradable film made from polycaprolactone. The film thickness may be between 5 microns and 300 microns, and the coating of the dry powder form of the inoculant may range from 0.001% to 50% by weight.

[0213] The electrostatic method of applying powder to a surface is described in detail in the Electrostatic Coating section on pages 74-89 of the Users Guide to Powder Coating (ISBN 0-87263-648-8), and its references are incorporated here. Several commercial electrostatic powder coating suppliers exist, including Nordson Corporation.

[0214] In one embodiment of the present invention, in order to provide the microbial inoculant with resistance to drying, a penetrating protective agent such as trehalose and a glycine-betaine compound may be added together with the inoculant.

[0215] In one embodiment of the present invention, a compound having the ability to retain moisture is added together with microorganisms beneficial to the plant. Non-limiting examples include guar gum, cellulose materials, alginates, or any other material having the natural ability to retain moisture.

[0216] In one embodiment of the present invention, PGA is a dry mixture containing different PGAs. In another embodiment of the present invention, PGA is in liquid form having a coating polymer. The plant enhancer may be dispersed in the polymer solution, solubilized in the polymer solution, or both. The solid content of the solution may be between 1% w / v and 60% w / v.

[0217] In one embodiment of the present invention, a water-soluble film containing PGA is prepared by a well-known solvent casting method, in which a polymer solution or aqueous dispersion is poured onto a smooth metal surface, and the water or solvent evaporates, leaving a smooth, thin film. The casting method for producing water-soluble films is a well-known process in the water-soluble film manufacturing industry. Solvent-cast films can be prepared using a commercially available slot-die coating process (slot-die coating equipment is available from Nordson).

[0218] A higher evaporation temperature for the production of PGA-filled films may be used when temperature-sensitive PGA is not required in the film and is not present in the polymer solution. Alternatively, when temperature-sensitive PGA is present in the polymer solution, a lower evaporation temperature may be used, and the temperature can be adjusted to minimize or avoid temperature-induced degradation or death of the active ingredient.

[0219] In one embodiment of the present invention, PGA is preferably selected from the group consisting of fungicides, bactericidal agents, insecticides, nematicides, fungicides, microorganisms, microbial inoculants, rodenticides, herbicides, attractants, repellents, plant growth regulators, nutrients, plant hormones, minerals, plant extracts, acaricides or mite control agents, mollusk killers, germination promoters, pheromones, biological agents, biopharmaceuticals, tagant, etc.

[0220] According to one embodiment of this specification, a polymer film is produced in which PGA is dispersed in the structure of the film. The amount of PGA may be between 1% and 50% of the weight of the dry film. Temperature-sensitive PGA may be blended with a low-melting-point polymer such as polycaprolactone (available in trade name CAPA series melt-extruded grade resins). Films filled with PGA can be extruded onto a PVOH film to form a two-layer film, or thermally laminated onto a PVOH film. PGEA stands for Plant Growth Enhancing Agent, and in this specification, it is a term used for individual agents or mixtures of different agents.

[0221] According to one embodiment of this specification, a polymer film is produced in which PGA is dispersed in the structure of the film. The amount of PGA may be between 1% and 50% of the weight of the dry film. Temperature-sensitive PGA may be blended with a low-melting-point polymer such as polycaprolactone (available in trade name CAPA series melt-extruded grade resins). The PGA-filled film may be extruded onto the seed surface or thermally laminated at a low temperature that does not damage the seeds. The PGA-filled film covers the seed surface to between 10% and 90%, preferably between 30% and 70%, and more preferably between 60% and 70%. The PGA is released gradually through the structure of the film or through elution from the film as the film degrades.

[0222] According to one embodiment of this specification, the coating composition is a dry mixture in particulate form, in which individual components are blended into the dry mixture, where the individual components are in the form of powders or in the form of composite particles containing one or more components. The dry coating composition can be applied to the surface of a film by electrostatic powder coating.

[0223] Ready-to-use PGAs are commercially available as fluid concentrates for seed treatment. These concentrates may be spray-coated or roll-coated onto the surface of a film. Requirements for higher delivery per seed can be met by using a more concentrated version of the product or by increasing the coating weight of the concentrate on the film. Non-limiting examples of commercially available fluid concentrates include: imidacloprid-48%FS (also available from Bayer as Gaucho®), thiomethoxam-30%FS, thyram-40%FS, and thiophanate-methyl + pyroclothribine 50%FS. Many fluid concentrates are commercially available, and custom and customized formulations can also be prepared by blending various compatible concentrates in ratios suitable for the appropriate delivery of the active ingredient to the seeds. Emulsion seed (ES) treatments are commercially available as oil-in-water emulsions of plant growth agents (PGAs). These PGAs can also be applied to the surface of a film by either spray or roll-coating. An example of a commercially available ES is metalaxyl-M-31.8%ES. Numerous ES treatment agents using different PGAs for seed application are commercially available and can be used for coating film surfaces.

[0224] Microcapsule suspensions of seed treatment PGAs such as FORCE ST from SYNGENTA can also be applied as a coating to the film surface. Dry or wettable powders (WP) of seed treatment PGAs are also commercially available. The WP may be dry-coated on the film surface or embedded in the film structure on one side of the film. Non-limiting examples include carbendazim-25%DS, tebuconazole-2.5%DS, carbosulfan-25%DS, and carboxyne-37.5+thyram-37.5%DS.

[0225] In one embodiment of the present invention, the coating composition may contain a suitable bactericide. Non-limiting examples of suitable bactericides include, for example, strobilurin bactericides, azole bactericides, conazole bactericides, triazole bactericides, amide bactericides, benzothiadiazole bactericides, or combinations thereof. In other embodiments, the bactericide may include azoxystrobin, metminostrobin, orysastrobin, paclobutrazol, acibenzol-S-methyl, chlorothalonil, mandipropamide, thiabendazole, chlorothalonil, triadimenol, cyprodinil, penconazole, boscalid, bixafen, fluopyram, fenpropidine, fraxapyroxad, penflufen, fluoxastrobin, benthenavalicarb, benthenavalicarb isopropyl, dimethomorph, flusulfamide, thiophanate-methyl, triticonazole, flutriafole, cyram, carboxyne, carbendazim, or combinations thereof.

[0226] Typical fungicides include captan (N-trichloromethyl)thio-4-cyclohexane-1,2-dicarboximide), thyram (tetramethylthioperoxydicarbondiamide; marketed under the trade name Proceed), metalaxyl (methyl N-(2,6-dimethylphenyl)-N-(methoxyacetyl)-DL-alaniic acid), and fludioxonil (4-(2,2-difluoro-1,3-benzodioxol-4-yl)-1-H-pyrrole-3-carbonitrile; blended with mephonoxam). Examples include iodine (marketed under the trade name Maxim XL), difenoconazole (marketed under the trade name Dividend 3FS), carbendadium iprodione (marketed under the trade name Rovral®), ipconazole, mephonoxam (marketed under the trade name Apron XL), tebuconazole, carboxyne, thiabendazole, azoxystrobin, prochloraz, and oxazixyl (N-(2,6-dimethylphenyl)-2-methoxy-N-(2-oxo-3-oxazolidinyl)acetamide). The fungicide may be included in the seed coating composition of the present invention in an amount of 0.0001 to 10% by weight, based on the total weight of the coated seeds.

[0227] In one embodiment of the present invention, the coating composition may contain a suitable nematicide, which may include, for example, avermectin nematicides, carbamate nematicides, organophosphate nematicides, benomyl, benkrothiaz, and combinations thereof. The nematicide may also include nematically active organisms such as bacteria and fungi. For example, Bacillus firmus, Bacillus cereus, Bacillus spp, Pasteuha spp, Pochonia chlamydosporia, Pochonia spp, and Streptomyces spp. An example of a ready-to-use nematicide is AVCTA® from Syngenta.

[0228] In one embodiment of the present invention, the coating composition may contain a suitable insecticide, and the insecticides that can be used include pyrethroids, organophosphates, caramoyl oximes, pyrazoles, amidines, halogenated hydrocarbons, neonicotinoids, and carbamates and their derivatives in some embodiments of the present invention. Particularly preferred classes of insecticides include organophosphates, phenylpyrazoles, and pyrethoids. Preferred insecticides are those known as terbuphos, chlorpyriphos, fipronil, chlorethoxyphos, tefluthrin, carbofuran, imidacloprid, and tebupyrimphos. Commercially available insecticides include imidacloprid (commercially traded as Gaucho®), clothianidin (commercially traded as Poncho® by Bayer), thiomethoxam (commercially traded as Cruiser® by Syngenta), and fipronil (commercially traded as Regent® by BASF). The insecticide may be included in the seed coating composition of the present invention in an amount of 0.001% to 10% by weight, based on the total weight of the coated seeds.

[0229] A mixture of insecticides and fungicides as PGA in the coating composition can also be used in the present invention. Some examples of drug mixtures are: clothianidin / methconazole; neonicotinoid / ethaboxam; neonicotinoid / 2-[2-(2,5-dimethylphenoxymethyl)phenyl]-2-methoxy-N-methylacetamide; neonicotinoid / torukurophosmethyl; metconazole / ethaboxam; 8 These are metconazole / 2-[2-(2,5-dimethylphenoxymethyl)phenyl]-2-methoxy-N-methylacetamide; etaboxam / 2-[2-(2,5-dimethylphenoxymethyl)phenyl]-2-methoxy-Nmethylacetamide; etaboxam / torukurophosmethyl; 2-[2-(2,5-dimethylphenoxymethyl)phenyl]-2-methoxy-N-methylacetamide / torukurophosmethyl; 2-[2-(2,5-dimethylphenoxymethyl)phenyl]-2-methoxy-N-methylacetamide / metalaxyl; 2-[2-(2,5-dimethylphenoxymethyl)phenyl]-2-methoxy-N-methylacetamide / mephenoxam; and 2-[2-(2,5-dimethylphenoxymethyl)phenyl]-2-methoxy-N-methylacetamide / ipconazole.

[0230] Suitable herbicides for PGA include triazine herbicides such as aryloxycarboxylic acid, aryloxyphenoxypropionate, cyclohexanedione oxime, hydroxybenzonitrile, sulfonylurea, triazolopyrimidine, trikethion, metrivudine, hexaxinone or atrazine; sulfonylurea herbicides such as chlorsulfuron; uracil herbicides such as renacil, bromacil or tarbacil; urea herbicides such as linulon, diuron, siduron or nevlon; acetanilide herbicides such as alachlor or metrachlor; thiocarbamate herbicides such as benthiocarb or trialate; and oxadia. Herbicides may be selected from the group including oxadiazolon herbicides such as chromazon; isoxazolidone herbicides, phenoxyacetic acid; diphenyl ether herbicides such as fluadifop, acyfluorphene, bifenox, or oxyfluorphene; dinitroaniline herbicides such as trifluralin; organophosphonate herbicides such as glufosinate salts and esters, glyphosate salts and esters; and / or dihalobenzonitrile herbicides such as bromoxynil or ioxinil, benzoic acid herbicides, dipyridyl herbicides such as paraquat; and other herbicides such as chromazon, carfentrazone, saflufenacil, and pyroxasulfone.

[0231] In some embodiments, the coating composition may also include one or more plant growth regulators. Suitable growth regulators may include, for example, potassium azide, 2-amino-4-chloro-6-methylpyrimidine, N-(3,5-dichlorophenyl)succinimide, 3-amino-1,2,4-triazole, 2-chloro-6-(trichloromethyl)pyridine, sulfathiazole, dicyandiamide, thiourea, guanylthiourea, or combinations thereof.

[0232] Microorganisms can be any bacteria, fungi, or viruses that have any beneficial effect in agriculture, such as controlling weeds, pests, or diseases, or improving plant growth, emergence, or yield. Some non-exclusive examples of bacteria that can be used include members of the genera Pseudomonas (e.g., P. fluorescein), Bradyrhizohium (e.g., B. japanicum), Serratia, Arthrobacter, Azospirillum, Rhizobiurn, and Bacillus.

[0233] Fungi that may be used in some embodiments of the present invention include Penicillium bilaiae, Trichoderma harzi nm, Fusarium oxysporium, Metarhizium anisopliae, Beauveria bassiana, Beauveria brongniartii, and Colletotrichum gloeosporioide.

[0234] In certain embodiments, the biological agent may include bacteria of the genera Actinomycetes, Agrobacterium, Arthrobacter, Alcaligenes, Aureobacterium, Azobacter, Bacillus, Beijerinckia, Bradyrhizobium, Brevibacillus, Burkholderia, Chromobacterium, Clostridium, Clavibacter, Comamonas, Corynebacterium, Curtobacterium, Enterobacter, Flavobacterium, Gluconobacter, and Hydrogenophaga.

[0235] Klebsiella, Metarhizium, Methylobacterium, Paenibacillus, Pasteuria, Photorhabdus, Phyllobacterium, Pseudomonas, Rhizobium, Serratia, Sphingobacterium, Stenotrophomonas, Streptomyces, Variovorax, and Xenorhabdus.

[0236] In some embodiments of the present invention, the bacteria are selected from the group consisting of Bacillus amyloliquefaciens, Bacillus cereus, Bacillus firmus, Bacillus lichenformis, Bacillus pumilus, Bacillus sphaericus, Bacillus subtilis, Bacillus thuringiensis, Bradyrhizobium japonicum, Chromobacterium subtsugae, Metarhizium anisopliae, Pasteuria nishizawae, Pasteuria penetrans, Pasteuria usage, Pseudomonas fluorescens, and Streptomyces lydicus.

[0237] In certain embodiments, the biological agent may include fungi of the genera Alternaria, Ampelomyces, Aspergillus, Aureobasidium, Beauveria, Colletotrichum, Coniothyrium, Gliocladium, Metarhizium, Muscodor, Paecilomyces, Penicillium, Trichoderma, Typhula, Ulocladium, and Verticillium. In other embodiments, the fungus may be Beauveria bassiana, Coniothyrium minitans, Gliocladium virens, Muscodor albus, Paecilomyces lilacinus, Penicillium bilaiae, Trichoderma asperellum, Trichoderma polysporum, or Trichoderma virens.

[0238] Non-exclusive commercially available microbial products for seed coating include HiStick N / T liquid inoculant from BASF, Vault® HP plus Integral® for soybean inoculant, also from BASF, Acceleron B-300 SAT from Monsanto, and Clariva® from Syngenta.

[0239] Nitrogen sources can be, for example, urea, oxamide, melamine, dicyanodiamide, ammonium nitrate, urea formaldehyde, magnesium ammonium nitrate, potassium nitrate, or combinations thereof. Phosphorus sources can be, for example, magnesium ammonium phosphate, ammonium metaphosphate, bone meal, brucite, calcined phosphate, calcium metaphosphate, calcium phosphate, calcium polyphosphate, diamide phosphate, magnesium calcium phosphate, phosphate rock, potassium phosphate, magnesium phosphate, monocalcium diammonium pyrophosphate, oxamidine phosphate, urea phosphate, potassium polyphosphate, or combinations thereof. NPK (N-P2O5-K2O) fertilizers can be selected from 14-14-14, 16-16-16, 20-20-20, 18-35-0, 16-0-12, 0-15-15, etc. Several grades of NPK containing other micronutrients are commercially available or can be prepared by blending or compression or through known chemical manufacturing processes.

[0240] Examples of micronutrients include boron, zinc, manganese, iron, copper, molybdenum, and chloride, which can be included as part of an immediate or long-term delivery agricultural composition.

[0241] Water-soluble films can be obtained by casting, blow molding, extrusion molding, or blow extrusion molding of blends of the same or different polymer materials. In one embodiment, suitable polymers, copolymers, or derivatives thereof are selected from polyvinyl alcohol, polyvinylpyrrolidone, polyalkylene oxide, polyacrylic acid, cellulose, cellulose ether, cellulose ester, celluloseamide, polyvinyl acetate, polycarboxylic acid and its salts, polyamino acids or peptides, polyamides, polyacrylamide, maleic acid / acrylic acid copolymers, starch and gelatin, polysaccharides, natural gums such as xanthan gum, and carrageenan, polyacrylate and water-soluble acrylate copolymers, methylcellulose, sodium carboxymethylcellulose, dextrin, ethylcellulose, hydroxyethylcellulose, hydroxypropyl methylcellulose, maltodextrin, polymethacrylate and combinations thereof, or polyvinyl alcohol, polyvinyl alcohol copolymer and hydroxypropyl methylcellulose and combinations thereof.

[0242] The disintegrant can be blended or dispersed into the film structure in an amount suitable for assisting the disintegration of the film upon contact with water. Soluble cellulose materials, such as hydrated alkali-crosslinked CMC (carboxymethylcellulose) as described in U.S. Patent No. 5,272,191A, may be used as the disintegrant. Polyvinyl alcohol (PVA) is a water-soluble synthetic polymer. Many different grades of PVA are commercially available. PVA polymers can be completely (98-100%), moderately (90-98%), or partially (70-90%) hydrolyzed. Partially hydrolyzed PVA polymers are most preferred. Modified or special grades of PVA polymers can also be used.

[0243] The preferred form of the polymer film in the present invention is a pre-formed film, with a pre-formed cold water-soluble film of PVOH being the most preferred. Cold water as defined in the present invention refers to a temperature of 5°C to 25°C.

[0244] Water-soluble films can be sourced from commercially available suppliers. Some non-exclusive examples of commercially available grade water-soluble films include SOLUBLON® brand PVA and PVA-copolymer film grades from Aicello, PVOH films from Aquafilm Inc. in Winston-Salem, or Monosol PVOH films from Chris Craft (Holland-IL), Kuraray, Nippon Gosei, and many other available water-soluble films.

[0245] In one embodiment of the present invention, the water-soluble film is soluble between 1°C and 50°C, preferably between 5°C and 30°C, and more preferably between 10°C and 20°C.

[0246] According to one embodiment of the present invention, the surface can be made non-stick by applying hot steam along with a plasticizer such as wax to one surface of a polymer film. The wax coating may be carried out separately before applying the film to the seed surface. This process is described in detail in US7201819 B2, which is incorporated herein by reference.

[0247] In another embodiment of the present invention, an inorganic mineral such as talc or CaCO3 (calcium carbonate) is blended into a commercially available thermoplastic PVOH resin to reduce the tackiness of the film. Furthermore, the addition of talc or calcium carbonate can reduce the overall cost of the PVOH film. The amount of inorganic mineral added can be 5% to 50% of the film's weight, more preferably 10% to 30%. A detailed manufacturing process for inorganic mineral-filled PVOH water-soluble films is described in the published paper (digital object identifier doi.org / 10.3139 / 217.2517).

[0248] Furthermore, a commercially available release agent may be used to reduce the tackiness of the water-soluble film surface. The release agent may be sprayed onto the surface of the PVOH film or applied as a roll coating. A water-based or solvent-based release agent may be used.

[0249] Several types of inorganic and organic anti-tack agents are commercially available. The coated seeds need to be easily flowable so that they can be planted in soil using commercially available planters. In one embodiment of the present invention, an organic or inorganic anti-tack agent or slip additive is added to a water-soluble polymer during manufacturing, incorporating the anti-tack agent / slip additive into the polymer structure. Upon cooling, some of these anti-tack agents / slip additives migrate toward the surface of the film, reducing the film's tackiness. The anti-tack agent may be selected from the group consisting of synthetic silica, limestone, natural silica, talc, calcium carbonate, zeolite, and organic additives such as hard waxes and fatty acid amides. Any chemical agent having the function of reducing the surface energy of a water-soluble film can be used as a coating agent to reduce the tackiness of the water-soluble film.

[0250] In some embodiments of the present invention, a polymer layer is coated onto 103b of film 103, and the polymer may be a liquid latex formulation. The latex coating on the surface is performed to improve the smoothness of the film. A commercially available aqueous latex, such as SB latex binder, can be applied to the surface of the film using a roll coater or spray coater, and the coating is dried under heat.

[0251] In one embodiment of the present invention, a multilayer film is used to coat a seed, and at least one layer is water-soluble. Here, the water-soluble layer is a first layer that is in contact with the surface of the seed. The second layer on top of the first layer may be a non-water-soluble film, and the second layer may be a biodegradable polymer film, and the second polymer film may have PGA dispersed in a polymer matrix, and the PGA may be encapsulated between the interface of the first layer and the second layer.

[0252] In another embodiment of the present invention, the water-insoluble layer of a multilayer film may have fine perforations in the film structure to allow for the permeation of oxygen and moisture. The permeation of oxygen and moisture in the layer may inhibit coating-induced germination delay in seeds. Perforation in the water-insoluble film may be achieved by a commercially available mechanical perforator, such as a hot needle perforator or a laser perforator.

[0253] In yet another embodiment of the present invention, the multilayer film may be manufactured by melt film co-extrusion or by extrusion coating lamination of one film onto another, for example, a non-water-soluble layer may be extruded onto a water-soluble film.

[0254] In yet another embodiment of the present invention, the water-soluble layer is coated on the water-insoluble layer as a liquid coating, and for example, the aqueous coating composition may be coated on a polycaprolactone film. Here, the water-soluble coating composition may include:

[0255] In yet another embodiment of the present invention, the biopolymer or natural polymer is selected from cellulose derivatives, polysaccharides, chitin and chitosan polymers, proteins, or gelatin. Numerous commercially available products are available for coating applications and can be used in the present invention.

[0256] The release of nutrients from the coating is designed so that the nutrients do not cause any phytotoxicity to the seeds or to the plants that germinate from the seeds.

[0257] In one embodiment of the present invention, the polymer-coated fertilizer is placed in the vicinity of polymer-coated seeds as produced according to an embodiment of the present invention, where the polymer-coated fertilizer provides nutrients by slow release, while the polymer coating of the seeds provides all the nutrients required by the seeds in the initial stage of growth, while the polymer-coated fertilizer provides the required nutrients and plant protection agents for the seeds after germination and in the initial stage of growth, and the polymer-coated seeds and the polymer-coated fertilizer may be planted using an automated planter, and the polymer-coated fertilizer may be placed within 6 inches in any direction of the polymer-coated seeds, preferably 5 inches from the position of the polymer-coated seeds, more preferably 4 inches, and the polymer-coated fertilizer does not provide nutrients immediately after germination during the initial stage of plant growth, and the requirements of the seeds immediately after germination and in the initial stage of growth are met by the provision of nutrients by the coating on the seeds. The polymer-coated fertilizer may have a plant protection agent mixed with the core of the fertilizer or in the polymer coating structure. The plant protection agent provided with the polymer-coated fertilizer may be a delayed early release.

[0258] According to one embodiment of the present invention, the polymer-coated seeds include the following;

[0259] a) Seeds for use in agricultural crop production,

[0260] b) A continuous polymer film layer that covers a substantial surface area of the seed with a continuous coating layer; wherein the film layer covers between 50% and 95% of the total surface area of the seed, more preferably between 70% and 90% of the total surface area of the seed, the coverage of the surface area is uniform, the polymer film covering the seed further includes a coating composition coated on the surface in contact with the seed and an anti-sticking coating on the opposite surface of the film, and the coating composition further includes one or more from the group consisting of a binder, a plasticizer, a wax, a stabilizer, a processing additive, a mineral, a pigment, and PGA; the polymer film coating is water-soluble, and here the coating composition is between 1% and 30% of the total weight of the seed, preferably between 0.1% and 10% of the total weight of the seed, more preferably between 0.1% and 5% of the total weight of the seed.

[0261] According to one embodiment of the present invention, the polymer-coated seed having an immediate and controlled release form of the coating on its constriction portion includes the following;

[0262] a) Seeds for use in agricultural crop production,

[0263] b) A continuous first polymer film layer that covers a substantial surface area of the seed with a continuous coating layer; wherein the film layer covers between 50% and 95% of the total surface area of the seed, more preferably between 70% and 90% of the total surface area of the seed, the coverage of the surface area is uniform, the polymer film covering the seed further includes a coating composition coated on the surface in contact with the seed and an anti-sticking coating on the opposite surface of the film, and the coating composition further includes one or more from the group consisting of a binder, a plasticizer, a wax, a stabilizer, a processing additive, a mineral, a pigment, and PGA; the polymer film coating is water-soluble, and here the coating composition is between 0.1% and 30% of the total weight of the seed, preferably between 0.1% and 10% of the total weight of the seed, more preferably between 0.1% and 5% of the total weight of the seed.

[0264] c) A second continuous polymer film covering a substantial surface area of ​​the seed, wherein the second continuous polymer film is applied on top of the first polymer film, the second continuous polymer film contains PGA dispersed in the matrix of the second continuous polymer film, the second continuous polymer film may be coated on the underside with a layer of coating composition, where the underside is defined as the surface of the second continuous polymer film in contact with the surface of the first continuous polymer film, the second continuous polymer film may be a biodegradable thermoplastic polymer film, the second continuous polymer film may cover a different surface area of ​​the seed than the first continuous polymer film, and the surface coverage of the second continuous polymer film may be shorter than that of the first continuous polymer film.

[0265] d) Seeds coated with a water-soluble first polymer film having a coating composition coated on its surface that comes into contact with the seed and covers a substantial surface area of ​​the seed release PGA upon contact with water, while a water-insoluble second continuous polymer film releases PGA gradually through the elution of PGA through the film matrix or through the release of PGA as the film decomposes in the soil.

[0266] According to one embodiment of the present invention, a method for producing polymer-coated seeds using a continuous polymer film includes the following:

[0267] a) Placing agricultural seeds on a housing cavity, where the housing cavity is adapted to draw a vacuum through an opening at the bottom of the cavity;

[0268] b) Applying a pre-formed film to the surface of the seed, wherein the pre-formed film comprises a polymer film having a continuous structure, a coating layer coated on a first surface of the polymer film, and a coating layer coated on a second surface of the polymer film;

[0269] c) Appropriately treat the polymer film to soften it so that it is flexible enough to be vacuum-formed, where appropriate treatment may involve applying heat or moisture to the film.

[0270] d) Applying a vacuum by pulling a film around the surface of the seed to coat the substantial surface area of ​​the seed with a polymer film.

[0271] According to one embodiment of the present invention, a method for coating polymer-coated seeds with a pre-formed polymer film includes the following:

[0272] a) Place the treated seeds on the housing cavity, where the seeds have been treated with PGA.

[0273] b) Applying a pre-formed polymer film having a continuous structure over multiple seeds housed in housing cavities, where each housing cavity houses at least one seed.

[0274] c) Surface treatment of the polymer film, which may include heating the film to soften it for thermoforming around the seeds, or applying moisture to soften the film.

[0275] d) Applying vacuum through the opening of the housing cavity so that a polymer film is coated around the surface of the pre-treated seeds.

[0276] According to one embodiment of the present invention, a method for encapsulating dry particulate matter between the surface of a seed and a polymer film enclosing the seed includes the following:

[0277] a) Placing the seeds in the housing cavity,

[0278] b) To induce surface changes on the surface of the seed, the surface of the seed is made to be surface charged.

[0279] c) Applying static electricity to the dry particulate material,

[0280] d) Bringing the charged dry particulate material close to the surface of the seed, where the opposite charge of the surface of the seed and the dry particulate material attracts the dry particulate material to adhere to the surface of the seed,

[0281] e) Heating or using moisture to soften the polymer film to make it flexible for vacuum forming,

[0282] f) Applying the softened film onto the seed and vacuum forming the softened film around the surface of the seed to cover the substantial surface area of the seed with a continuous polymer film, thereby trapping the dry particulate material between the seed surface and the polymer film.

[0283] In certain embodiments of the present invention, the polymer film is a water-soluble polymer, and the water-soluble polymer film is soluble in water at a temperature between 1 °C and 30 °C.

[0284] In certain embodiments of the present invention, the polymer film is a water-insoluble polymer, and the water-insoluble polymer film is slowly decomposed.

[0285] In certain embodiments of the present invention, the polymer film is made of a biodegradable thermoplastic polymer.

[0286] In certain embodiments of the present invention, the polymer film is made of a non-biodegradable thermoplastic polymer.

[0287] In certain embodiments of the present invention, the polymer film is made of a polymer of natural origin.

[0288] In one embodiment of the present invention, the coating composition comprises a latex binder, a pigment, a stabilizer, and a PGA, wherein the latex binder may be water-soluble, and at least one PGA is selected from the group comprising insecticides, fungicides, microbial inoculants, and fertilizers.

[0289] According to another embodiment of the present invention, dust-free and freely flowing polymer-coated seeds are produced in a continuous coating process by holding seeds at a certain distance from each other and then applying a liquid coating with a high solid content to the exposed surface of the seeds. A cylindrical drum having a housing cavity can be used to contain and hold the seeds, and a series of roller-coaters can be employed to apply the coating to the surface of the held seeds.

[0290] The coating may be dried after each application. A perforated conveyor belt may also be used to hold the seeds in place. The coating composition may be any commercially available application seed coating or seed treatment chemical.

[0291] The high-speed continuous seed coating method includes the following:

[0292] a) Hold multiple seeds at a certain distance from each other so that they do not come into contact with each other during coating.

[0293] b) Applying a layer of the coating composition to the exposed surface of the seed, wherein the coating composition has a solid content of between 1% and 70% by weight, preferably between 10% and 50%, more preferably between 20% and 50%, and the coating covers between 50% and 95% of the total surface area of ​​the seed, preferably between 70% and 95%, more preferably between 80% and 90%.

[0294] c) Allow the coating to dry to some extent; however, the coating does not need to be completely dry before applying the second coating layer (if necessary).

[0295] d) (Optional) Applying another coating layer,

[0296] e) The process may be repeated as many times as necessary.

[0297] Moisture barrier coated film for coating fertilizer Moisture barrier coatings, also known as barrier polymer dispersion coatings, are understood to refer to a coating technique in which latex (i.e., an aqueous dispersion of fine polymer particles) is applied to the surface of a base polymer film so that it forms a solid, non-porous or microporous film after drying. The purpose of barrier dispersion coatings is to achieve a barrier layer against water or water vapor.

[0298] In one embodiment of the present invention, a composite polymer film is manufactured by coating a moisture barrier layer onto a polymer film. The composite film comprises a base polymer film and a moisture barrier layer coated on the base polymer film. The moisture barrier polymer may be a dispersion or an emulsion polymer. The moisture barrier dispersion latex can be selected from, but is not limited to, PVDC, polyethylene, styrene-acrylic / styrene-butadiene-based formulations, and waxes (natural and synthetic).

[0299] Other moisture barrier coatings can be achieved by applying SiOx-based formulations, AlOx polymer nanocomposites, or mineral-filled compositions. Barrier coatings of base polymer films for improving moisture barrier properties are well known.

[0300] In one embodiment of the present invention, the biodegradable polymer film is coated with a moisture barrier dispersion polymer such that the biodegradable film constitutes at least 70% of the total weight of the combined dry film, and the moisture barrier constitutes 30% of the total weight of the combined dry film, more preferably in a ratio of 80% and 20%, and even more preferably in a ratio of at least 90% and 10%.

[0301] In another embodiment of the present invention, the proportion weight of the base polymer in the barrier-coated base polymer film is at least 90% of the total weight of the barrier-coated base polymer film.

[0302] For example, commercially available moisture barrier latexes that may be selected include, but are not limited to, PVDC latex sold under the brand name Diofan by Solvay Corporation of Belgium, PVDC latex from Asahi Kasei Corporation of Japan, Daran series PVDC latex from Borchers, Inc. of the United States, and Vaporcoat 2200 from Michelman, Inc. of the United States.

[0303] In one embodiment of the present invention, a 9-micron thick PLA film is coated with Diofan 0A50 PVDC latex using a Meyer rod coater, and a 1-micron dry PVDC thickness is achieved on the PLA after the coating has dried. The composite film comprising the PLA film and the dried PVDC film is applied to granular fertilizer to encapsulate the fertilizer within the layers of the composite film.

[0304] In another embodiment of the present invention, an adhesion-promoting primer is required to coat a moisture barrier latex onto a base polymer film. Commercially available primers that can be used in the embodiments include Neorez 610 grade from DSM of the Netherlands, Emuldur 381A from BASF of Germany, and Takelac A-310 Takenate A-3 / Ethyl Acetate from Mitsui Chemicals of Japan. The primer is primarily a polyurethane-based adhesive with high polarity to provide anchoring to the barrier latex. In some embodiments, corona or plasma treatment of the base film before coating with the primer may also help to form a receptive surface for the application of the primer coating.

[0305] In another embodiment of the present invention, latex can be applied to both sides of a base polymer film.

[0306] In yet another embodiment of the present invention, the latex may be formulated to contain a small amount of plant growth agent (PGA).

[0307] Any of the available coating methods, such as Meyer rod coating, slot die coating, roll coating, liquid spray coating, gravure coating, and screen printing coating, can be used to apply the primer and moisture barrier coating.

[0308] In one embodiment of the present invention, AlOx may be applied via a vacuum deposition method.

[0309] In yet another embodiment of the present invention, a moisture barrier coating may be applied to a cellulose-based film such as commercially available cellophane, and this barrier-coated cellulose film is then coated onto fertilizer granules by softening the film with moisture and then vacuum forming it around a substrate.

[0310] Alternative Embodiments The above description is intended to be purely illustrative, and those skilled in the art will recognize that modifications can be made to the described embodiments without departing from the scope of the disclosed invention. This disclosure can be embodied in other specific forms without departing from the subject matter of the claims. This disclosure is intended to cover and encompass all preferred modifications in the art. Modifications that fall within the scope of the invention will be obvious to those skilled in the art in light of the examination of this disclosure, and such modifications are intended to fall within the appended claims. Furthermore, the claims should not be limited by the preferred embodiments shown in the examples, but should be given the broadest interpretation consistent with the description as a whole.

Claims

1. A method for manufacturing a coated substrate, To fix the base material to the base, Applying a first coating layer to the substrate, The coating method involves wrapping the first coating layer around the substrate to substantially coat the substrate, wherein the first coating layer has excess coating extending around the base toward the substantially coated substrate. To remove the base from the substrate, Forming a tail portion from the excess coating of the first coating layer, wherein the tail portion extends at an angle from the surface of the substrate, and The tail portion is melted, and the melted tail portion is laminated onto the first coating layer, thereby sealing the tail portion to the first coating layer and encapsulating the substrate. A method that includes this.

2. Before fixing the substrate to the base, apply the second coating layer to the base to partially coat the base, and To deliver the substrate to the base which is partially coated, The method according to claim 1, further comprising:

3. The method according to claim 2, comprising heating the second coating layer to thermoform the second coating layer around the base.

4. The method according to claim 2 or 3, wherein the tail portion is formed from excess coating of the first coating layer and a portion of the second coating layer.

5. The method according to any one of claims 1 to 4, wherein the base material is a fertilizer, a pesticide, a fertilizer-pesticide combination product, a pharmaceutical tablet, a nutritional supplement tablet, an agricultural seed, a solid food article, or a water-soluble solid core.

6. The method according to any one of claims 1 to 5, wherein the first coating layer comprises at least one of a polymer, a polymer processing additive, a mineral, a pigment, a pesticide, an antimicrobial agent, a ripening inhibitor, a plant growth agent, a micronutrient, a pharmaceutically active ingredient, poly(vinyl alcohol), a wax, an adhesive resin, an adhesive, a fungicide, an insecticide, a nematicide, a herbicide, a microorganism, and / or a fertilizer.

7. The method according to any one of claims 1 to 5, wherein the first coating layer is at least one of a thermoformable film, a vacuum formable film, a biodegradable film, a non-biodegradable film, a water-soluble film, and / or a non-enteric film.

8. A system for manufacturing coated substrates, A feed device configured to feed a substrate into a receiving section, wherein the receiving section comprises a feed device having a mating base, A first coating device configured to apply a coating layer to the receiving portion, A biasing device configured to bias the coating layer around a portion of the substrate and the base, The base is movable relative to the mating receiving portion through an opening defined in the mating receiving portion, and the base is configured to move between an extended position in which the base extends into the mating receiving portion to receive the substrate on the base, and a withdrawn position in which the base is withdrawn from the mating receiving portion, separating the base from the substrate and coating layer to form a coated substrate having a tail portion, and A sealing system for sealing the tail portion to the coating layer, A system equipped with these features.

9. The system according to claim 8, further comprising a second coating apparatus configured to apply a second coating layer to each base in order to partially coat the base before the base receives the substrate.

10. The system according to claim 8 or 9, wherein each base is configured to translate along its longitudinal axis through the opening of the mating receiving portion without horizontal displacement in order to engage with or disengage from the base material.

11. The system according to any one of claims 8 to 10, wherein the biasing device is a vacuum pump configured to generate vacuum pressure in the opening and bias the coating layer around a portion of the substrate and the base.

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