Coater Rotator With Fine Particles For Uniform Coating
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Solution Overview
Problem
Existing coating technologies experience unevenness in the application of treatment liquids on sheet materials due to the scraping off of liquid by rollers, leading to inconsistent coating amounts between contacted and non-contacted areas.
Innovation Solution
The use of rotators with fine particles on the circumferential surfaces of conveyance rollers, which point-contact the coated surface to reduce liquid scraping and maintain consistent coating, with particle diameters larger than the average film thickness to secure adhesive force and protrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rollers are used to convey the sheet material, then the sheet material can be conveyed efficiently, but the coating liquid is scraped off the coated surface causing unevenness in coating amount
Solution Approach 1:
The roller surface is modified with fine particles that have different properties from the base roller material. These particles create a localized region on the roller surface that has reduced adhesion to the coating liquid, allowing the roller to convey the sheet while minimizing coating liquid removal. This local modification of surface properties resolves the contradiction between conveyance efficiency and coating uniformity.
Solution Approach 2:
The surface properties of the roller are changed by attaching fine particles with specific characteristics (small diameter, low adhesion to coating liquid). This parameter change in surface adhesion allows the roller to maintain contact with the sheet material for conveyance while reducing the harmful scraping effect on the coating liquid, thus improving both conveyance efficiency and coating uniformity.
2Manufacturing precision
If the roller surface is made smooth to reduce scraping, then coating uniformity improves, but conveyance ability decreases
Solution Approach 1:
Instead of making the entire roller surface smooth, fine particles are attached to create localized non-adhesive regions. These particles provide the necessary surface characteristics to reduce coating liquid adhesion while the overall roller structure maintains its conveyance function. This local quality approach preserves conveyance efficiency while improving coating uniformity.
Solution Approach 2:
The roller surface is created as a composite structure combining the base roller material with fine particles. This composite surface has properties that neither component alone would provide - the base material provides structural integrity and conveyance ability, while the fine particles provide reduced adhesion to coating liquid, achieving both good conveyance and uniform coating.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration significantly reduces unevenness in the coating amount between contacted and non-contacted areas, ensuring a consistent application of the treatment liquid across the sheet material.
Implementation Method 1
the rotator has a plurality of fine particles on a circumferential surface of the rotator, wherein the fine particles have a particle diameter larger than an average film thickness of the applied coating liquid
Data Source
AI summary
A coater includes a coating device and a rotator. The coating device is configured to apply a coating liquid on a sheet material. The rotator is configured to contact a coated surface of the sheet material to which the coating liquid is applied in the coating device. The rotator has a plurality of fine particles on a circumferential surface of the rotator.