Methods for coating a foil using a coating system with an adjustable gap between two rollers

A method for coating a foil with a coating system, the coating system comprising:

• a dispensing unit arranged to apply a material on a first foil advanced through a first gap between a first roller supported by a first holder and a second roller supported by a second holder;
• a first linear actuator mounted on the second holder for adjusting a position of a first arm;
• a second linear actuator mounted on the second holder for adjusting a position of a second arm;
• a first piezoelectric sensor mounted on the first holder for detecting a contact of the first arm on the first piezoelectric sensor;
• a second piezoelectric sensor mounted on the first holder for detecting a contact of the second arm on the second piezoelectric sensor;
• a piston configured to bias the second holder towards the first holder, wherein the first arm and the second arm are configured to counter the piston's biasing of the second holder towards the first holder when the first arm and second arm are extended;
• and a controller configured to control the first linear actuator and the second linear actuator so as to adjust a position of the second roller relative to a position of the first roller, thereby adjusting a width of the first gap between the first roller and the second roller;
• the method comprising:
• applying the material by the dispensing unit on the first foil located within the first gap between the first roller supported by the first holder and the second roller supported by the second holder;
• advancing the first foil through the first gap between the first roller supported by the first holder and the second roller supported by the second holder, the first gap being associated with a thickness of a layer of the material applied on the first foil;
• biasing the second roller by the piston towards the first roller;
• adjusting the position of the first arm by the first linear actuator mounted on the second holder, wherein extension of the first arm by the first linear actuator counters the biasing of the second roller towards the first roller;
• adjusting the position of the second arm by the second linear actuator mounted on the second holder, wherein extension of the second arm by the second linear actuator counters the biasing of the second roller towards the first roller;
• detecting, by the first piezoelectric sensor mounted on the first holder, the contact of the first arm on the first piezoelectric sensor;
• detecting, by the second piezoelectric sensor mounted on the first holder, the contact of the second arm on the second piezoelectric sensor;
• and
• controlling with the controller the first linear actuator and second linear actuator so as to adjust the position of the second roller relative to the position of the first roller, thereby adjusting the width of the first gap between the first roller and the second roller.