Rolling Head Movable Rod Inlet Lip Meniscus Control
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Solution Overview
Problem
Existing rolling heads with movable rods struggle to produce high grammage coatings and are limited by viscosity range, while heads without rods are sensitive to contamination and cannot generate low grammage coatings efficiently, leading to defects such as thickening, bubbles, and longitudinal defects.
Innovation Solution
A rolling head design featuring a movable rod with a specifically configured inlet lip, including a straight internal side, a flat face, and an external side with a step, which ensures proper meniscus positioning and pressure distribution to accommodate a wide range of flow rates and viscosities, preventing defects like bubbles and thickening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rolling heads with movable rods are used, then low grammage coatings can be produced with good uniformity, but high grammage coatings greater than 50 g/m² cannot be achieved
Solution Approach 1:
The rod is made movable rather than fixed, allowing it to adapt its position dynamically. The rod can move vertically to accommodate different grammage requirements, enabling the same device to produce both low grammage coatings with good uniformity and high grammage coatings up to and beyond 50 g/m².
Solution Approach 2:
The invention changes the operational parameters of the rolling head by allowing the rod position to vary. By adjusting the rod's vertical position and movement characteristics, the system can optimize performance for different grammage ranges, extending adaptability from only low grammage to both low and high grammage coatings.
2Adaptability or versatility
If rolling heads without movable rods are used, then high grammage coatings can be produced, but low grammage coatings cannot be generated efficiently and contamination sensitivity increases
Solution Approach 1:
The movable rod provides dynamic control over the coating process. For high grammage coatings, the rod can be positioned to allow greater fluid accumulation, while for low grammage coatings, the rod's movement and positioning ensure precise control to maintain uniformity and prevent defects.
Solution Approach 2:
The movable rod acts as a feedback mechanism that responds to coating conditions. The rod's position and movement are influenced by the fluid flow and coating thickness, allowing automatic adjustment to maintain coating quality across different grammage ranges and reduce contamination sensitivity.
3Productivity
If the distance between the head and substrate is not adequate, then coating efficiency decreases, but bubbles and thickening defects appear
Solution Approach 1:
The movable rod dynamically adjusts the gap between the head and substrate during operation. This dynamic adjustment ensures an adequate distance is maintained to prevent air entrapment and bubbles, while also preventing excessive fluid accumulation that causes thickening defects, thereby maintaining both efficiency and quality.
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 new rolling head design extends the range of working flow rates and viscosities, enabling the production of both high and low grammage coatings while minimizing defects, including bubbles and thickness irregularities, and maintaining coating homogeneity.
Implementation Method 1
pressurised fluid circulates through a fluid passage channel until reaching a discharge region
Implementation Method 2
The rod and the substrate force the fluid flow into the discharge region, generating a fluid layer on the substrate
Implementation Method 3
the flow transfer in the meniscus (curved separation surface between the coating fluid and the atmospheric air)
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A rolling head comprising: a fluid passage channel (1) that opens into a fluid discharge region (2); a movable rod (3) located in the fluid discharge region (2), arranged after the first edge (1a) of the fluid passage channel and close to the perimeter of a rotating roller (4) on which a substrate is arranged; and an inlet lip (5) provided with a straight internal side (5a) that is oblique to the perimeter of the rotating roller (4) and that defines the second edge (1b) of the fluid passage channel, of a flat face (5b) facing the rotating roller (4) and an external side (5c, 5d, 5e), the latter provided with a step (5c, 5d).