System and method for coating discrete patches on a moving substrate

A web coating system comprising:

• a transport roll supporting a substrate movable in a first direction at a first speed;
• a reservoir containing a coating;
• a first pump in fluid communication with the reservoir to pump fluid from the reservoir;
• and
• a coating distribution device disposed downstream of the first pump and including an inlet in fluid communication with the first pump, the coating distribution device including a motor and a second pump configured to deposit at least a portion of the coating from the first pump onto the substrate via an outlet;
• and
• a controller in operative communication with the transport roll and the motor, the controller programmed to determine a speed of the transport roll and to generate a control signal to control the predetermined flow rate(s) of the second pump, the second control signal based on a predetermined size and thickness of an area of coating to be applied to the substrate,
• wherein the second pump is controlled by the controller at different flow rates to generate the predetermined size and thickness of the coating area on the substrate.

A method of applying a coating to a substrate, the method comprising:

• pumping the coating from a reservoir to a coating distribution device using a first pump;
• applying the coating to the substrate using the coating distribution device, the coating distribution device including a motor and a second pump driven by the motor;
• controlling the flow of the coating generated by the second pump through the coating distribution device via a controller at first flow rates to deposit the coating onto the substrate via an outlet;
• and
• controlling the flow of the coating generated by the second pump through the coating distribution device via the controller at a second flow rate to stop deposition of the coating on the substrate.