Double-Sided Coating Layout for Stable Web Height and Film Uniformity
Find Innovative SolutionsGenerate Solutions
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, leading to uneven film thickness and particle generation due to deflection and vibration, especially when the base material is floated in the air.
Innovation Solution
A double-sided coating device with a conveying mechanism that includes a roll to support the base material on its circumferential surface, a drawing section to adjust the base material's position, and a floating device to maintain it at a target height, preventing contact with the second die and reducing deflection and vibration, while ensuring uniform coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the base material is floated in the air during coating application, then the coating device can be more compact, but the position and flatness of the base material cannot be maintained, leading to uneven film thickness
Solution Approach 1:
A back-up roll is introduced as an intermediary support element to hold the base material during coating application. The back-up roll provides mechanical support to maintain the base material's position and flatness while allowing the coating head to apply coating material to the opposite surface, thus preventing uneven film thickness while keeping the device relatively compact.
2Manufacturing precision
If the base material is supported by a back-up roll during coating application, then position and flatness are maintained, but particles are generated due to abrasion between the base material and the roll
Solution Approach 1:
The invention extracts and removes the back-up roll from the system, eliminating the source of particle generation through abrasion. Instead of supporting the base material with a physical roll that contacts and wears the material, the system uses a different approach to maintain position and flatness during coating application.
3Manufacturing precision
If a thin film coating device uses a nozzle portion that contacts the base material, then deflection and vibration are suppressed, but particles are generated due to abrasion
Solution Approach 1:
The invention introduces a back-up roll as an intermediary support element that prevents base material deflection and vibration during coating application without requiring the coating nozzle to contact the base material. This maintains coating film uniformity while avoiding particle generation from abrasion between the nozzle and base material.
Data Source
AI summary
A double-sided coating device includes: a conveying mechanism for a base material that includes a first surface and a second surface; a first die that applies a first coating material onto the first surface; and a second die that applies a second coating material onto the second surface. The conveying mechanism includes: a roll that conveys the base material, in which the position at which the base material separates from the circumferential surface is higher than a target coating height of the base material; and a drawing section that draws the base material such as to bring the base material closer to the target coating height.