Layer-by-layer coating apparatus and method

Patent metadata

Field	Value
Publication number	US-11717849-B2
Application number	US-202117248328-A
Country	US
Kind code	B2
Filing date	Jan 20, 2021
Priority date	Oct 12, 2015
Publication date	Aug 8, 2023
Grant date	Aug 8, 2023

Abstract

Apparatus and method useful for, among other things, providing a layer by layer coating of materials on a substrate.

First claim

What is claimed is:

1. A method of making a coating on a substrate, the method comprising
(a) tensioning a substrate in the form of a belt around a first roller and a second roller such that at least a portion of the belt faces a first deposition station and a second deposition station that is downstream from the first deposition station,
the first deposition station comprising
a first self-limiting monolayer forming material depositing element to deposit a first liquid comprising a first self-limiting monolayer forming material on the belt for affixing a monolayer of a first self-limiting monolayer forming material to the belt, and

the second deposition station comprising
a second self-limiting monolayer forming material depositing element for affixing at least a monolayer of a second self-limiting monolayer forming material to the belt; and wherein

(b) moving the belt around the first roller and the second roller while engaging the first self-limiting monolayer forming material depositing element to apply a first liquid comprising a first self-limiting monolayer forming material on the belt;
(c) engaging a first directional gas curtain producing element that is positioned downstream from the first deposition station to provide a gas curtain that simultaneously meters and dries the first liquid on the belt while leaving at least a monolayer of first self-limiting monolayer forming material on the belt, and wherein the method does not include a rinsing step to remove excess first liquid from the belt;
(d) engaging the second self-limiting monolayer forming material depositing element to apply a second liquid comprising a second self-limiting monolayer forming material on the belt; and
(e) engaging a second directional gas curtain producing element that is positioned downstream from the second deposition station to provide a gas curtain that simultaneously meters and dries the first liquid on the belt while leaving at least a monolayer of first self-limiting monolayer forming material on the belt.

2. The method of claim 1 , wherein the step of applying a first liquid comprising a first self-limiting monolayer forming material on the belt comprises spraying the first liquid on the belt.

3. The method of claim 1 , wherein the method does not include a rinsing step to remove excess second liquid from the belt.

4. The method of claim 1 , wherein the belt does not stop moving until at least one of a pre-determined number of monolayers are deposited, a pre-determined amount of time passes, a pre-determined thickness is achieved, or a pre-determined optical, chemical, or physical property is achieved.

5. The method of claim 1 , wherein the first and second self-limiting monolayer forming materials are applied to the belt by sprayers.

6. The method of claim 1 , wherein the method is a roll-to-roll process.

7. The method of claim 1 , wherein the first directional gas curtain producing element is directed at the belt at an angle of between 80° and 90° to the belt.

8. The method of claim 1 , wherein the belt moves at a speed of at least 0.25 m/s for the duration of the method.

9. The method of claim 1 , wherein a gap between a gas outlet of the first directional gas curtain producing element and the belt is no more than 0.8 mm.

Assignees

• 3M Innovative Properties Company

Inventors

• Kawakami Ellison G
• Kolb William Blake
• Van Lengerich Henrik B

Classifications

• B05D1/36 Primary

  Successively applying liquids or other fluent materials, e.g. without intermediate treatment · CPC title

• B05B1/14

  with multiple outlet openings (B05B1/02, B05B1/26 take precedence); with strainers in or outside the outlet opening · CPC title

• B05C5/0245

  for applying liquid or other fluent material to a moving work of indefinite length, e.g. to a moving web (B05C5/0241, B05C5/0254, B05C5/027, B05C5/0283 take precedence) · CPC title

• B05C11/06

  with a blast of gas or vapour · CPC title

• B05D1/02

  performed by spraying · CPC title