Method for producing a non-uniform coating on a substrate

Patent metadata

Field	Value
Publication number	US-9950339-B2
Application number	US-201614993216-A
Country	US
Kind code	B2
Filing date	Jan 12, 2016
Priority date	Dec 22, 2009
Publication date	Apr 24, 2018
Grant date	Apr 24, 2018

Abstract

A roll coater can be modified by the addition of one or more needle tubes that supply coating fluid to the roll coater in discrete locations across the face of the coating roll. The needle tubes supply a localized band of coating material onto the coating roll superimposed over the uniform coating layer already present on the surface of the coating roll from an upstream coating pond creating a stripe pattern over the uniform coating layer. By varying the relative speeds of the coating rolls in the coater, the width of the stripe can also be adjusted.

First claim

What is claimed is:

1. A method of coating a substrate with a coating apparatus, the method comprising:
applying a first coating uniformly onto the face of a coating roll;
applying a second coating in one or more discrete stripes over the first coating; and
transferring the first and second coatings onto the substrate,
wherein the coating apparatus comprises a five roll coater including the coating roll, a W 3 roll, a W 2 roll, a W 1 roll and a W 00 roll, the substrate wrapping at least a portion of the W 3 roll and entering the five roll coater at an infeed nip between the W 3 roll and the W 2 roll, the W 1 roll nipped with the W 2 roll, the coating roll nipped with the W 1 roll, and the W 00 roll nipped with the coating roll.

2. The method of claim 1 wherein the applying the first coating uniformly onto the face of a coating roll comprises supplying a coating pond at the infeed nip between the W 00 roll and the coating roll with a first coating solution.

3. The method of claim 1 wherein applying the second coating in one or more discrete stripes over the first coating comprises supplying at least one needle tube with a second coating and impinging the second coating onto the face of either the W 2 , the W 1 , or the coating roll.

4. The method of claim 3 wherein an impingement angle between a longitudinal axis of the needle tube and a tangent line to the roll's surface at the point of impingement is between about 0 degrees to about 60 degrees.

5. The method of claim 3 wherein the second coating comprises a second coating stream exiting from the at least one needle tube.

6. The method of claim 1 wherein applying the second coating in one or more discrete stripes over the first coating comprises supplying at least one needle tube with a second coating and impinging the second coating into an infeed nip between the W 2 and the W 1 roll or between the W 1 and the coating roll.

7. The method of claim 6 wherein the second coating comprises a second coating stream exiting from the at least one needle tube.

8. The method of claim 6 wherein a width of the one or more discrete stripes is varied by adjusting the relative speed between the rolls forming the infeed nip.

9. The method of claim 1 , wherein the second coating is applied via at least one needle tube being disposed adjacent the coating roll on the side opposite the W 00 roll.

Assignees

• 3M Innovative Properties Co

Inventors

• Maier Gary W

Classifications

• B05C9/06

  for applying two different liquids or other fluent materials, or the same liquid or other fluent material twice, to the same side of the work · CPC title

• C09J7/403

  characterised by the structure of the release feature · CPC title

• B05D1/28 Primary

  performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers · CPC title

• B05C1/00

  Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating (B05C5/02, B05C7/00 take precedence) · CPC title

• D21H23/58

  Details thereof, e.g. surface characteristics, peripheral speed · CPC title