Curtain Coating Separation Member for Base Material Flapping Control
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Solution Overview
Problem
Curtain coating devices face issues with base material flapping and variation in uncoated area width, leading to increased cutting-off amounts and material loss during the slitting process.
Innovation Solution
A curtain coating device with a separation member having a receiving portion inclined downward and a base material supporting member to stabilize the base material, preventing flapping and maintaining uniform uncoated width, while a coating width control member adjusts the curtain-like film to minimize uncoated areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a groove mechanism is used to collect coating liquid at both end portions of the curtain, then the uncoated portion is formed on both ends of the sheet, but the width of the uncoated portion varies and requires larger cutting-off margins
Solution Approach 1:
The patent introduces a base material supporting member as an intermediary element positioned between the curtain coating member and the groove mechanism. This supporting member stabilizes the base material during the coating process, preventing excessive movement and ensuring that the uncoated portions formed by the groove mechanism maintain consistent width. By adding this intermediary support element, the system achieves both the formation of uncoated portions and their uniform width, thereby reducing the cutting-off margin required.
2Reliability
If a slitter is used to remove the uncoated portion with larger width than target, then no uncoated area remains after slitting, but productivity decreases due to increased material loss
Solution Approach 1:
The patent replaces the conventional approach of using a wide slitter blade with a more precise mechanical control system consisting of the base material supporting member and optimized groove mechanism. Instead of relying on excessive cutting capacity, the system uses the supporting member to control base material position and the groove mechanism to form precise uncoated portions. This substitution of the mechanical cutting approach with a controlled coating approach reduces material loss while ensuring complete removal of uncoated areas.
3Device complexity
If the base material is allowed to flap during conveyance, then the coating process is simpler, but the uncoated area width varies requiring larger cutting-off margins
Solution Approach 1:
The patent applies preliminary action by positioning the base material supporting member before the coating process occurs. This supporting member pre-establishes the correct position and stability of the base material during conveyance under the curtain coating member. By preparing the base material in advance with proper support, the system achieves uniform uncoated portion width without requiring complex adjustments during the coating process itself, thus maintaining relative simplicity while improving precision.
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
The solution effectively prevents base material flapping, maintains uniform uncoated width, reduces cutting-off amounts, and maximizes the utilization of coated areas, thereby improving productivity.
Implementation Method 1
a receiving portion inclined downward from inside to outside in a width direction of the curtain-like film, and separates an end portion of the curtain-like film having flowed down by receiving the end portion with the receiving portion
Data Source
AI summary
A curtain coating device includes a curtain coating member, a conveyance unit, a separation member, and a base material supporting member. The curtain coating member creates a curtain-like film of coating liquid and makes the curtain-like film flow down. The conveyance unit conveys a base material to which the curtain-like film is to be applied. The separation member includes a receiving portion inclined downward from inside to outside in a width direction of the curtain-like film, and separates an end portion of the curtain-like film having flowed down by receiving the end portion with the receiving portion above the base material. The base material supporting member is disposed inside in the width direction of the curtain-like film than the receiving portion of the separation member, and supports the base material on an upper side flat portion while the base material is being conveyed.