Sealing Chamber Coating System for Precise Film Thickness Control
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Solution Overview
Problem
Current coating systems for applying barrier coatings on substrates face challenges in achieving precise film thickness in one pass and efficient drying, particularly for water, liquid, and oxygen barriers, and are costly due to the need for multiple anilox rollers and extensive make-ready times.
Innovation Solution
A modular coating system with a sealing chamber that includes a coating form roller, a metering roller, and a sealing chamber with blades and end seals to prevent drying and control coating solution flow, utilizing a pumping system for precise coating thickness and recirculation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional anilox systems with chambered doctor blade are used to apply coating, then a fixed coating film thickness can be achieved, but the film thickness can only be changed by replacing expensive anilox rollers which increases cost and make ready time
Solution Approach 1:
The patent replaces the static anilox roller system with a dynamic blade positioning system where the doctor blade can be adjusted vertically to change coating film thickness. The blade is mounted on a movable support structure that allows continuous adjustment of the blade-to-roller gap, enabling dynamic control of coating thickness without replacing components.
Solution Approach 2:
The invention changes the controlling parameter from fixed roller geometry to adjustable blade position. By varying the vertical position of the doctor blade relative to the roller surface, the coating film thickness parameter can be continuously adjusted. This is achieved through mechanical adjustment mechanisms that change the spatial parameter of blade alignment.
2Adaptability or versatility
If multiple anilox rollers with different engraving patterns are purchased to achieve different film thicknesses, then various coating thicknesses can be obtained, but the cost increases substantially and make ready time increases
Solution Approach 1:
The patent creates a universal coating system where a single roller combined with an adjustable doctor blade can perform the function of multiple specialized anilox rollers. The blade positioning mechanism allows one configuration to serve multiple thickness requirements, making the system multi-functional and eliminating the need for multiple dedicated components.
Solution Approach 2:
The system allows for quick preliminary adjustment of the blade position before coating operations begin. The adjustable support structure enables operators to pre-set the desired coating thickness by positioning the blade at the appropriate height, allowing rapid changeover between different coating specifications without extensive setup time.
3Productivity
If coating solution is applied on rollers in traditional systems, then coating can be applied to substrate, but the coating solution on roller may dry when the system is operated which affects coating quality
Solution Approach 1:
The patent extracts the coating solution supply from the traditional roller immersion method and replaces it with a controlled delivery system. The coating solution is applied directly to the roller surface through a metering mechanism rather than being held in a reservoir on the roller, eliminating the drying issue while maintaining continuous coating application.
Data Source
AI summary
A system may include: a coating form roller; a metering roller adjacent to the coating form roller; and a sealing chamber. The sealing chamber may include first and second blades that engage with the coating form roller and the metering roller, respectively.