Hot-Melt Adhesive Roller Transfer Coating
Solution Overview
Problem
Existing roll transfer coating methods for hot-melt adhesives expose the adhesive to the substrate surface, leading to contamination from dust and impurities, temperature changes, and deterioration, and fail to apply adhesives in a thin film state, necessitating the use of unnecessary components like smoother rolls.
Innovation Solution
A roll transfer coating method that applies hot-melt adhesive in a thin film state only to the protruding faces of a pattern roll, eliminating the need for smoother rolls and preventing adhesive exposure, thereby reducing contamination and maintaining a clean environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hot-melt adhesive is fed via a slot nozzle with a smoother roll, then the adhesive can be applied to the coating roll, but the adhesive is exposed on the route to the substrate surface causing contamination and temperature deterioration
Solution Approach 1:
The patent removes the smoother roll component from the adhesive application system. By directly applying adhesive to the protrusion pattern surface of the coating roll without passing through a smoother roll, the adhesive is no longer exposed to contamination sources and temperature fluctuations in the intermediate transfer path, thus eliminating the harmful effects while maintaining application precision
Solution Approach 2:
The protrusion pattern surface of the coating roll serves as an intermediary that receives adhesive directly from the slot nozzle and transfers it to the substrate. This intermediary structure allows precise adhesive placement without requiring an additional smoother roll, thereby preventing exposure-related contamination and temperature deterioration
2Reliability
If a smoother roll is used to feed hot-melt adhesive to the coating roll, then the adhesive can be circulated, but unnecessary components increase device complexity
Solution Approach 1:
The smoother roll is completely removed from the adhesive feeding system. The patent achieves reliable adhesive feeding by applying adhesive directly to the protrusion pattern surface of the coating roll through a slot nozzle, eliminating the need for a smoother roll and its associated gear pump and duct system, thus reducing device complexity while maintaining feeding reliability
Solution Approach 2:
The coating roll with protrusion pattern surface serves multiple functions: it receives adhesive directly from the slot nozzle, acts as the transfer medium to the substrate, and eliminates the need for a separate smoother roll. This multi-functionality reduces the number of components while maintaining adhesive feeding reliability
3Manufacturing precision
If hot-melt adhesive is applied in a thick film state, then the adhesive can be easily transferred, but the adhesive application amount increases and efficiency decreases
Solution Approach 1:
The patent applies adhesive only to the protrusion pattern surfaces of the coating roll, creating localized adhesive regions rather than a uniform thick film. This local quality approach ensures sufficient adhesive is present for reliable transfer to the substrate while minimizing overall adhesive consumption, thus improving coating efficiency without compromising transfer quality
Solution Approach 2:
Instead of applying adhesive uniformly across the entire coating roll surface, the patent applies adhesive only to the necessary protrusion pattern areas. This partial action approach reduces adhesive application amount while maintaining sufficient adhesive availability for complete substrate coverage, thereby improving productivity
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 method effectively reduces adhesive application to the substrate, prevents overheating and volatile component dispersion, and allows for precise coating by applying adhesive only to protruding faces, enhancing the coating process and work environment.
Implementation Method 1
applying means for applying the hot-melt adhesive in a thin film state to the protruding faces of the pattern roll
Implementation Method 2
transferred to a substrate surface by moving the substrate sandwiched between the pattern roll and an impression roll and brought into pressure contact with the pattern roll and the impression roll
Data Source
Figure 1
Figure 2~3
Figure 4(a)~6(b)
AI summary
The purpose of the present invention is to apply a hot-melt adhesive in a thin-film state only to top surfaces of pattern roller protrusions. This roller transfer application method for a hot-melt adhesive is characterized: in that a coater head having a slot in a direction towards an axis center of the roller is provided facing a pattern surface of the pattern roller; and by supplying the hot-melt adhesive, which is supplied from a hot-melt adhesive supply device, in a thin-film state to a pattern top surface of the pattern roller, and thus the thin-film hot-melt adhesive is only supplied to the top surfaces of pattern roller protrusions. This method is further characterized by supplying the hot-melt adhesive only to the top surfaces of the pattern roller protrusions by opening an on-off-type hot-melt adhesive supply control valve, which is attached to the coater head, when an adhesive opening on the bottom surface of the coater head is facing application zones on the pattern surface of the pattern roller. The present invention has the effect of satisfactorily maintaining a work environment by preventing contamination of the device periphery.