Sealed Coating Apparatus for High Viscosity Tissue
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Solution Overview
Problem
Traditional coating methods are poorly suited for applying high viscosity coatings to tissue webs due to contamination issues and inability to maintain a sealed environment, which affects the application efficiency and quality of coatings on high-speed tissue machines.
Innovation Solution
A sealed coating apparatus with a metering device at its trailing edge, designed to apply a thin layer of coating material to an applicator roll, which is then transferred to the tissue web, providing a sealed environment for the coating material and allowing high viscosity coatings to be applied effectively while preventing contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional coating methods are used, then coating application is possible, but contamination of coating material by dust and particulate occurs
Solution Approach 1:
The patent implements a sealed coating chamber that creates a controlled environment, isolating the coating material from external contaminants such as dust and particulate. The sealing mechanism includes a coating chamber with seals at the interface between the chamber and applicator roll, preventing contamination while maintaining coating application functionality.
2Reliability
If high viscosity coating materials are used, then coating quality on tissue improves, but application difficulty increases
Solution Approach 1:
The patent employs a pressurized coating material supply system where coating material is delivered under pressure into the sealed chamber. This hydraulic/pneumatic pressure mechanism facilitates the flow and application of high viscosity coating materials onto the tissue web, overcoming their inherent resistance to flow and enabling effective coating application.
Solution Approach 2:
The patent incorporates an adjustable metering device that can be positioned at varying distances from the applicator roll surface. This dynamic adjustment capability allows precise control over the coating gap, enabling operators to optimize coating parameters for different viscosity levels and achieve consistent coating quality across varying material properties.
3Productivity
If tissue machines run at high speed, then productivity increases, but coating application quality deteriorates
Solution Approach 1:
The patent utilizes a continuous applicator roll that rotates in sync with the tissue web movement, maintaining continuous contact and coating application throughout the process. This continuous action ensures uniform coating distribution even at high machine speeds, preventing defects that could arise from intermittent or discontinuous coating methods.
Solution Approach 2:
The metering device positioning system allows dynamic adjustment of the coating gap distance, enabling operators to optimize coating parameters for different operating speeds. By adjusting the gap, the system maintains consistent coating application quality across a range of machine speeds, preserving manufacturing precision while accommodating high productivity requirements.
Data Source
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AI summary
The present invention relates to an apparatus for applying a coating, preferably a high viscosity coating to a supported web, preferably tissue. The apparatus of the present invention comprises a sealed coating chamber that can be supplied with coating material under pressure. The chamber further comprises a metering device at its trailing edge, which applies a thin layer of coating material to an applicator roll. In general, the coater is designed to have a small footprint, allowing it to fit into tight locations and be readily adapted for use in existing tissue manufacturing and converting processes. The coater also has the advantage of having a sealed coating chamber, which permits coating material to be supplied under pressure and preventing contamination of the coating material by debris common to the coating process.