Dielectric Strip Metallization With Uncoated Strips for Roll Adhesion
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Solution Overview
Problem
Existing methods for coating dielectric substrates with metal layers cannot achieve repeated or double-sided coating due to the loss of dielectric properties when substrates are initially charged, limiting the adhesion improvement benefits to single-sided coating processes.
Innovation Solution
The method involves coating dielectric substrates with a metal layer in a way that leaves at least one longitudinal strip free, allowing previous or new charge to be maintained, ensuring improved adhesion on the coating roll, and using vacuum vapor deposition to apply subsequent metal layers while avoiding coating in these strips through treatments like oil application or masking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the substrate is coated with metal layer over its entire width, then the coating completeness is improved, but the ability to maintain charge and adhesion is worsened
Solution Approach 1:
The substrate width is segmented into coated regions and uncoated free strips. The coating device applies metal layer only to specific regions while leaving longitudinal free strips uncoated. This segmentation allows different regions to serve different functions: coated regions provide product coverage while uncoated regions maintain dielectric properties for charging and adhesion.
Solution Approach 2:
Different regions of the substrate are given different properties: coated regions have metal layer for product coverage while uncoated free strips maintain the original dielectric substrate properties. This local differentiation allows the substrate to simultaneously achieve coating completeness in required areas and charge retention in uncoated areas.
2Temperature
If the substrate is charged to improve adhesion on coating roll, then the cooling effect is improved, but the applicability to metal-coated substrates is worsened
Solution Approach 1:
The substrate is divided into coated regions and uncoated free strips. The uncoated free strips maintain dielectric properties that enable charging by electron beam, while coated regions receive the metal layer. This segmentation allows charging and cooling to be applied to metal-coated substrates by targeting the uncoated regions.
Solution Approach 2:
The uncoated free strips act as intermediaries that enable the charging process to work on metal-coated substrates. These strips provide the necessary dielectric properties for electron beam charging, serving as a bridge that allows the charging mechanism to function even when most of the substrate is metal-coated.
3Productivity
If repeated coating is performed on metal-coated substrates, then the productivity is improved, but the charging capability is worsened
Solution Approach 1:
The substrate width is segmented into multiple coated regions separated by uncoated free strips. This segmentation allows the substrate to undergo repeated coating cycles while the uncoated free strips consistently provide charging capability between coating operations, enabling high-speed repeated coating of both sides.
Solution Approach 2:
The uncoated free strips continuously provide dielectric properties throughout the coating process, enabling continuous charging capability during repeated coating operations. This ensures that the substrate can be repeatedly charged and coated on both sides without interruption to the charging function.
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
Enables repeated and double-sided coating processes with improved adhesion and cooling, maintaining charge in non-coated strips to enhance substrate adhesion and heat dissipation, achieving higher coating rates and layer thicknesses without increasing processing time.
Implementation Method 1
The substrate is charged, for example, with the aid of an electron beam, which is directed onto the substrate before contact with the coating roll
Implementation Method 2
The substrate is coated in particular by means of a vacuum vapor deposition method
Data Source
AI summary
The invention relates to a method and a device for coating a strip-type, flexible, dielectric substrate with a metal layer on a coating roll over which the substrate is guided in the longitudinal direction of the substrate during the coating process. In order to improve the adhesion of the substrate on the coating roll during the coating process, the substrate is charged. The substrate is coated with a first metal layer, wherein, in the longitudinal direction of the substrate, at least one free strip remains which is not coated with the metal layer, and the coated substrate is provided with a second metal layer.