Knit Transfer Roller for Uniform Container Rim Coating
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Solution Overview
Problem
Existing methods for applying coatings to the rim of containers, such as jars and bottles, often result in nonuniform thickness due to the arbitrary geometry of the surface, leading to issues like leakage from heat-sealing primers caused by glass alkaline migration, especially when the containers are stored for extended periods.
Innovation Solution
A method using a transfer roller with a tubular warp or weft knit surface, specifically a 2×1 rib construction made of para-aramid fibers, to apply a uniform coating to the rim of containers, preventing nonuniformities and ensuring a consistent thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a transfer roller with conventional surface material is used to apply coating to the rim, then the coating process is simple and fast, but the coating thickness is nonuniform with greater thickness at the back of the coating
Solution Approach 1:
The roller surface is covered with a tubular knit fabric that acts as a flexible thin film layer. This fabric layer conformally contacts the rim surface and transfers coating uniformly through its flexible, adaptable structure, eliminating the nonuniform thickness problem while adding minimal structural complexity.
Solution Approach 2:
The invention changes the physical parameters of the roller surface by using a tubular knit fabric with specific properties (thread count, knit pattern, material composition) to achieve uniform coating transfer. The fabric's porosity, surface texture, and elasticity are optimized to ensure consistent coating application.
2Reliability
If the coating thickness is increased to prevent alkaline migration during long-term storage, then leakage prevention is improved, but nonuniformities in coating thickness are magnified and aesthetic quality deteriorates
Solution Approach 1:
The tubular knit fabric on the roller creates a flexible, conformal contact with the rim, ensuring that even at increased coating thickness, the coating is applied uniformly across the entire surface. The fabric's ability to adapt to surface geometry prevents thick spots and thin spots, maintaining both reliability and precision.
Solution Approach 2:
The roller continuously applies coating material through the tubular knit fabric as it contacts the rim, ensuring uniform and continuous coverage. This continuous action prevents interruptions or variations in coating thickness, achieving both the required thickness for reliability and uniformity for precision.
3Productivity
If spraying method is used to apply coating, then coating speed is fast and productivity is high, but the annular geometry of the rim causes nonuniform coating and potential overcoating of inner wall and base
Solution Approach 1:
The tubular knit fabric on the roller provides localized, controlled coating application only where the roller contacts the rim. This local quality approach ensures coating is applied precisely to the rim surface without overspray to the inner wall or base, maintaining uniformity while achieving high productivity through continuous roller contact.
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 achieves a uniform coating thickness on the rim of containers, enhancing the durability and adhesion of seals, while preventing leakage issues by maintaining a consistent primer thickness, thus improving both aesthetic and technical aspects.
Implementation Method 1
a method for applying a liquid to the rim of a container by transfer from a roller
Implementation Method 2
The knit preferably has a rib construction, encompassing cardigan rib, Richelieu and 1×1, 2×1, 2×2, 3×3 and 4×4 constructions, etc.
Data Source
AI summary
The invention provides:a method for applying a liquid to the rim of a container by transfer from a roller whose surface is composed of a tubular warp or weft knit of 2×1 rib construction;a glass jar or equivalent container whose rim has a coating of varnish, adhesion promoter or heat-sealing primer formed by an application method;a jar or equivalent container comprising a seal heat-sealed to the rim.