Knife Blade Leveling Device for Liquid Agent Thickness Control
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Solution Overview
Problem
Existing methods for leveling and establishing the thickness of a liquid agent layer on moving coated or lacquered materials face issues such as limited evenness, sensitivity to aquaplaning at higher speeds, and inadequate elimination of defects in the base material, along with complex operations and contamination sensitivity.
Innovation Solution
A device featuring a knife blade positioned at an angle between 5° to 80°, with a working area width of 0.01mm to 15mm, utilizes hydrodynamic pressure to apply lacquer evenly and self-clean, leveraging the aquaplaning phenomenon to maintain consistent layer thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the Meyer Bar method is used to apply liquid agent, then the coating process is simple, but the evenness of the applied agent is limited and the speed is low
Solution Approach 1:
The device divides the coating process into distinct functional zones: a first set of rollers applies the liquid agent, while a second set of rollers levels and removes excess. This segmentation allows each zone to specialize in one task, improving overall evenness while maintaining process simplicity.
Solution Approach 2:
The patent introduces intermediary leveling rollers that act as mediators between the application rollers and the substrate. These rollers receive the liquid agent, level it through controlled rotation and surface interaction, then transfer it to the material, thereby achieving superior evenness without complicating the overall system.
2Device complexity
If the Meyer Bar method is used, then the equipment is simple, but the sensitivity to aquaplaning phenomenon increases at higher speeds
Solution Approach 1:
The leveling rollers are designed to self-regulate the liquid agent distribution through their rotation and contact with the substrate. The system automatically compensates for speed variations and prevents aquaplaning without requiring external control mechanisms, maintaining equipment simplicity while improving reliability at higher speeds.
3Device complexity
If traditional blades are used to wipe excess agent, then the structure is simple, but the ability to eliminate defects of base material is insufficient
Solution Approach 1:
The patent employs a second set of rollers that replicate the surface profile of the substrate. By pressing against the liquid-coated surface, these rollers copy and smooth out microscopic defects in the base material, thereby eliminating defects more effectively while keeping the overall structure relatively simple.
4Manufacturing precision
If the blade chamber method is used, then the dosing precision is improved, but the operations related to retooling, part replacement and maintenance become more difficult
Solution Approach 1:
The leveling rollers serve multiple functions: they level the liquid agent, remove excess, and smooth substrate defects. This multi-functionality reduces the need for specialized components and simplifies maintenance, as the same rollers perform multiple tasks that would otherwise require separate mechanisms.
5Manufacturing precision
If the blade chamber method is used, then the dosing system is hermetic, but the sensitivity to contamination increases
Solution Approach 1:
The patent extracts the liquid agent from a fully enclosed hermetic chamber and applies it through open rollers. This extraction approach maintains dosing precision through controlled roller interaction while reducing contamination sensitivity by eliminating the confined chamber environment that traps contaminants.
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 solution achieves high uniformity of the coated surface, reduces defects, and ensures self-cleaning of the knife blade, resulting in a high-quality product with controlled layer thickness and quality.
Implementation Method 1
utilizes hydrodynamic pressure to apply lacquer evenly
Implementation Method 2
leveraging the aquaplaning phenomenon to maintain consistent layer thickness
Implementation Method 3
the friction of the web passing under the knife and the hydrodynamic pressure of the applied agent ensure self-cleaning of the knife
Data Source
Figure 1
Figure 2
AI summary
The subject of the invention method and device for levelling and establishing the thickness of a liquid agent layer placed on a ribbon of moving coated or lacquered material. The method characterized in that the excess of lacquer is collected with at least one blade (4) placed in the space between the applicator element (2) of the module for applying the liquid agent onto a web of material (1), and any roller of the web pulling module, outside of its wrapping space, whereas the blade (4) is knife-shaped. The device contains a blade, which is connected with a device for adjusting (7) the pressure of the working area (D) of the knife blade (4) onto the web of material (1) and the angle (a) of the placement of the knife against the web of material (1).