Non-uniform Discontinuous Coating via Dynamic Manifold Control
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Solution Overview
Problem
Existing methods for applying coatings to substrates lack the ability to create complex, non-uniform patterns efficiently, particularly in forming discontinuous patterns where one coating material's dispensing rate can intersect with another without overlapping, which is crucial for various applications like air barrier membranes and drug delivery patches.
Innovation Solution
A method involving a distribution manifold with multiple dispensing outlets that creates relative motion between the substrate and outlets, varying the dispensing rate of coating materials to form discontinuous patterns, including periods where the dispensing rate is zero or random, allowing patterns from different outlets to intersect without overlapping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coating material is dispensed continuously from multiple outlets, then complete coverage is achieved, but overlapping patterns are created that compromise functionality
Solution Approach 1:
The system employs periodic interruption of coating material flow from multiple dispensing outlets, creating discontinuous patterns that intersect without overlapping. The flow is alternately stopped and restarted in a coordinated sequence, ensuring that when one outlet dispenses material, adjacent outlets remain inactive, thereby preventing overlap while maintaining complete substrate coverage through the intersecting discontinuous patterns.
Solution Approach 2:
The invention dynamically controls the dispensing rate of coating material from multiple outlets, varying it in a predetermined fashion to create discontinuous patterns. The system adjusts the dispensing rate between active and zero states in a coordinated manner, allowing patterns from different outlets to intersect without overlapping, thereby achieving precise pattern formation while maintaining material distribution.
2Adaptability or versatility
If multiple coating materials are applied simultaneously, then complex patterns are formed, but control over non-overlapping intersections becomes difficult
Solution Approach 1:
The system segments the dispensing control into distinct temporal phases for multiple coating materials. Each coating material outlet is controlled independently with segmented flow interruption sequences, allowing complex intersecting patterns to be formed while maintaining precise control over where each material is deposited. This segmentation enables coordinated dispensing where materials intersect without overlapping.
Solution Approach 2:
The system employs feedback control mechanisms to monitor and adjust the dispensing rate of multiple coating materials in real-time. By continuously monitoring the dispensing process and making adjustments to maintain the predetermined dispensing rates, the system ensures that complex patterns are formed with precise control over intersections, preventing overlap while achieving the desired pattern complexity.
3Manufacturing precision
If dispensing outlets are stationary, then simple uniform patterns are created, but complex non-uniform patterns cannot be formed
Solution Approach 1:
The invention translates the plurality of dispensing outlets in a direction non-parallel to the substrate motion direction, creating dynamic motion patterns that generate complex non-uniform discontinuous patterns on the substrate. This dynamic translation of outlets, combined with periodic flow interruption, enables the formation of versatile patterns including stripes, grids, and other geometric configurations while maintaining precise control over pattern uniformity through coordinated dispensing sequences.
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 the creation of complex, non-overlapping patterns on substrates, enhancing the functionality of coated articles such as air barrier membranes and drug delivery patches by ensuring precise control over coating distribution.
Implementation Method 1
varying a rate of dispensing of the first coating material in a predetermined fashion to form a discontinuous pattern of the first coating material on a major surface of the substrate
Data Source
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AI summary
A process for applying a coating material onto a substrate as a non-uniform discontinuous pattern of coating material, the method including the present disclosure describes a method of applying a coating material onto a substrate, including providing a first distribution manifold having a cavity and a multiplicity of first dispensing outlets in fluid communication with the cavity, creating relative motion between a substrate and the dispensing outlets in a first direction; dispensing a first coating material from the dispensing outlets while maintaining the relative motion and translating the multiplicity of dispensing outlets in a second direction non-parallel to the first direction, and varying a rate of dispensing of the first coating material in a predetermined fashion to form a discontinuous pattern of the first coating material on a major surface of the substrate. Useful non-uniformly patterned coated articles can be prepared using the process.