Double-Sided Coating Layout for Stable Web Positioning
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Solution Overview
Problem
Conventional double-sided coating devices face challenges in maintaining the position and flatness of base materials during the application of coating materials on both sides, leading to uneven thickness and generation of particles due to abrasion, which affects product quality.
Innovation Solution
A double-sided coating device that includes a conveying mechanism with a roll supporting the base material on one surface, a drawing section to adjust the position, and a second die for applying the second coating material while minimizing contact, using suction parts and floating devices to maintain stability and prevent abrasion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the base material is floated in the air during second coating application, then the base material can be processed without contact support, but the position and flatness of the base material cannot be maintained, leading to uneven coating thickness
Solution Approach 1:
A back-up roll is introduced as an intermediary support element to provide contactless support for the base material during the second coating application. The back-up roll allows the base material to be supported without direct contact between the coating die and the base material, thereby maintaining both ease of operation and manufacturing precision.
2Reliability
If the base material is supported by the back-up roll at the first surface coated with undried first coating material, then the base material can be supported during second coating application, but the second coating material cannot be applied onto the second surface
Solution Approach 1:
The base material is conveyed in a vertical orientation with the first surface facing upward and the second surface facing downward. The back-up roll supports the base material from below, allowing the second coating die to apply coating material onto the second surface without interference from the first surface coating. This dimensional arrangement resolves the conflict between support stability and coating application capability.
3Object-affected harmful factors
If the base material is floated in the air during second coating, then contactless processing is achieved, but deflection and vibration of the base material occur
Solution Approach 1:
The back-up roll serves as a mediator that provides stable support for the base material during the second coating application. It prevents deflection and vibration by maintaining consistent contact with the base material, thereby eliminating the harmful effects of air-floating while still preventing direct contact between the coating die and the base material.
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 device effectively suppresses deflection and vibration of the base material, reducing particle generation and ensuring uniform coating thickness, thereby improving product quality.
Implementation Method 1
a roll that is positioned on the upstream side of the second die in the conveyance direction, that conveys the base material while supporting it at the second surface on a circumferential surface of the roll
Implementation Method 2
a drawing section that is positioned between the roll and the second die in the conveyance direction and that draws the base material such as to bring it closer to the target coating height
Data Source
Figure 1
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AI summary
A double-sided coating apparatus 1 is provided with: a conveying mechanism 2 for conveying a base material 10 having a first surface 10a and a second surface 10b; a first die 4 for applying a first coating material 18 to the first surface 10a; and a second die 6 for applying a second coating material 20 to the second surface 10b on a downstream side from the first die 4. The conveying mechanism 2 comprises: a roll 12 which conveys the base material 10 while supporting the second surface 10b on the peripheral surface of the roll, and sends out the base material 10 with the first surface 10a coated with the first coating material 18 directed upward and the second surface 10b uncoated with the second coating material 20 directed downward, the roll 12 being configured such that the position at which the base material 10 leaves the peripheral surface of the roll is higher than the target coating height for the base material 10; and a leading-in part 14 drawing in the base material 10 so that the base material 10 approaches the target coating height between the roll 12 and the second die 6.