Edge contact substrate transport method and apparatus

An apparatus for transporting a web material, the apparatus comprising:

• least two support rollers, wherein:
• a first support roller engages a first edge region of a first side of the web material having a length substantially greater than the width thereof, and
• a second support roller engages a second edge region of the first side of the web material, and wherein each of the rollers has a width that is substantially less than the width of the web material;
• and
• wherein each of the support rollers is rotatable on a bowed shaft, and wherein at least one of the support rollers is at an angle θ in a plane x-y with respect to a direction x normal to a longitudinal axis y of the shafts, and wherein the angle θ is greater than about 0° and less than about 6°.

A web path for conveying a web material, comprising:

• at least two support rollers contacting a single major surface of the web material, wherein the web material is of indefinite length and has a first and a second edge, and wherein the web material wraps about the support rollers at a wrap angle of about 90° to about 230°, the support rollers comprising:
• a first support roller contacting a first edge region of the web material, and
• a second support roller contacting a second edge region of the web material opposite the first edge, such that the web material comprises an un-contacted region between the first and the second support roller comprising at least about 50% of the width of the web material;
• and
• wherein at least one of the first support roller and the second support roller are angled with respect to the direction of motion of the web.

A method, comprising:

• engaging a first edge region on a first side of a web material with a first support roller, wherein the first support roller is rotatable on a first end of a shaft, and wherein the web material has a length substantially greater than the width thereof;
• engaging a second edge region on the first side of the web material with a second support roller, wherein the second support roller is rotatable on a second end of the shaft opposite the first end thereof, and wherein a central region between the first roller and the second roller and comprising at least about 80% of a width of the web material is free of support from a roller;
• and
• wrapping the web material about the first roller and the second roller at an angle of about 90° to about 230′;
• and,
• orienting at least one of the support rollers at an angle θ in a first plane x-y with respect to a direction x normal to a longitudinal axis y of the shaft, wherein the angle θ is greater than about 0° and less than about 6°.

A method for coating a web material, the method comprising:

• engaging a first edge region on a first side of the web material with a first support roller, wherein the first support roller is rotatable on a first end of a shaft, and wherein the web material has a length substantially greater than the width thereof;
• engaging a second edge region on the first side of the web material with a second support roller, wherein the second support roller is rotatable on a second end of the shaft opposite the first end thereof, and wherein a central region comprising at least about 80% of a width of the web material between the first roller and the second roller is free of support from a roller;
• bowing the shaft an amount sufficient to orient the first and the second support rollers at an angle θ in a first plane x-y with respect to a direction x normal to a longitudinal axis y of the shaft, wherein the angle θ is greater than about 0° and less than about 6°;
• transporting the web material over the first and the second support rollers;
• applying a coating composition to a second side of the web material opposite the first side;
• and
• processing the coating composition to form a coating layer on the second side of the web material.