Method for automatic film thickness control

A method of coating a major surface of a continuously longitudinally advancing article with a uniform thickness of a liquid coating material consisting essentially of:

• (a) positioning an extended surface a distance away from a major surface of the article said distance disposed to produce a coating of a desired thickness, which major surface is extended in a direction of article advancement along an advancement path, so that the extended surface traverses the path and is translatable in a direction perpendicular to the article major surface, with the major surface and the extended surface forming a distance gap therebetween which is variable in response to extended surface translation;
• while
• (b) continuously advancing the article successively past the extended surface;
• while
• (c) supplying liquid coating material to the gap in sufficient quantities to fill the gap substantially and generate a hydrodynamic force on the extended surface which urges the extended surface away from the article major surface as the article advances past the extended surface;
• while
• (d) sensing repetitively distance between the extended surface and the article major surface;
• while
• (e) continuously urging the extended surface toward the article major surface by exerting on the extended surface a load having a variable magnitude;
• and while
• (f) varying the load in response to the sensing, so as to reduce the difference between the sensed distances and the distance disposed to produce a coating of the desired thickness, thus producing a layer of liquid coating material having a uniform thickness on the advancing article.

A method for controlling the thickness of a liquid coating being applied to a rapidly advancing major surface of an elongated article, which comprises:

• selecting a thickness for the liquid coating;
• providing a continuously advancing article having a major surface;
• providing a head including an extended surface having an opening, the extended surface being fixedly attached to said head and oriented transversely to the direction of article advancement;
• mounting the head, with the extended surface oriented transversely to the direction of article advancement for longitudinal movement of the head with respect to the major surface of the article, the major and extended surfaces defining a gap therebetween, said gap variable with respect to extended surface longitudinal movement;
• supplying a liquid coating material to the gap through the opening in the extended surface in a quantity sufficient to substantially fill the gap as the major surface advances by the extended surface;
• repetitively measuring the gap using at least one measuring device fixedly attached to said head and positioned behind and adjacent to the extended surface to obtain a sensed distance value;
• and
• moving the extended surface of the head longitudinally with respect to the major surface to reduce the difference between the sensed distance value and the selected thickness, thus producing a layer of liquid coating material controlled to a selected film thickness on the advancing article.