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US 5,641,544 AGranted
Method and apparatus for applying thin fluid coatings
AssigneeMinnesota Mining and Manufacturing Company
InventorsKurt C. Melancon, Carl R. Kessel, William K. Leonard
Life of this patent
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Abstract
A system for coating a substrate with an ultra-thin layer includes moving the substrate through a coating station and forming a composite layer including a coming fluid and a carrier fluid. The composite layer flows at a rate that is sufficiently high to form a continuous flowing fluid bridge of composite layer to the substrate surface and to contact the substrate with the flowing composite layer to interpose the coating layer between the substrate and the carrier fluid. The carrier fluid is removed while leaving the coating fluid deposited on the substrate as a coating layer.
Claims34
A method of coating a substrate with a layer comprising the steps of:
- moving the substrate along a path through a coating station;
- forming a composite layer comprising at least one coating fluid and at least one carrier fluid having a formulation different from that of each coating fluid, wherein the carrier fluid comprises a liquid at the ambient condition at the coating station;
- flowing the carrier fluid at a rate that, by itself, is sufficient to form a continuous flowing fluid bridge of composite layer to the substrate for the coating width, wherein the carrier fluid is continuous;
- contacting the substrate with the flowing composite layer to interpose the coating layer between the substrate and the carrier fluid;
- and
- removing carrier fluid while leaving the coating fluid deposited on the substrate as a coating layer, wherein none of the components of the carrier fluid is part of the coating and at least a portion of all of any carrier fluid components are removed, thereby permitting the carrier fluid to act as a type of transfer device.
3 more elements
A method of coating a substrate with a layer comprising the steps of:
- moving the substrate along a path through a coating station;
- forming a composite layer comprising at least one coating fluid and at least one carrier fluid having a formulation different from that of each coating fluid;
- flowing the composite layer at a rate that is sufficient to form a continuous flowing fluid bridge of composite layer to the substrate for the coating width, wherein the carrier fluid portion of the composite layer is continuous;
- contacting the substrate with the flowing composite layer to interpose the coating layer between the substrate and the carrier fluid;
- and
- removing at least a portion of the carrier fluid while leaving the coating fluid deposited on the substrate as a coating layer comprising at least one of mechanical doctoring, draining by gravity, centrifugal removal blowing, and suction, solidification of carrier followed by doctoring, magnetic attraction, gelation of the carrier then doctoring, gelation of the coating then doctoring, solidification of the coating then doctoring, adsorption of the carrier fluid, and chemical bonding of the coating followed by mechanical removal of carrier.
3 more elements
A method of coating a substrate with a layer comprising the steps of:
- moving the substrate along a path through a coating station;
- forming a composite layer comprising at least one coating fluid and at least one carrier fluid having a formulation different from that of each coating fluid;
- flowing the composite layer at a rate that is sufficient to form a continuous flowing fluid bridge of composite layer to a transfer surface for the coating width, wherein the carrier fluid portion of the composite layer is continuous;
- contacting the transfer surface with the flowing composite layer to interpose the coating layer between the transfer surface and the carrier fluid;
- removing carrier fluid while leaving the coating fluid deposited on the transfer surface as a coating layer;
- and
- transferring some portion of the coating fluid to the substrate from the transfer surface.
4 more elements
A method of coating a substrate with a layer comprising the steps of:
- moving the substrate along a path through a coating station;
- forming a composite layer comprising at least one coating fluid and at least one carrier fluid having a formulation different from that of each coating fluid using carrier fluid that is immiscible with the coating fluid with which it forms an interface and wherein the carrier fluid has wetting properties that cause it to not wet the surface of the coating fluid-coated substrate;
- flowing the composite layer at a rate that is sufficient to form a continuous flowing fluid bridge of composite layer to the substrate for the coating width, wherein the carrier fluid portion of the composite layer is continuous;
- contacting the substrate with the flowing composite layer to interpose the coating layer between the substrate and the carrier fluid;
- and
- removing at least a portion of the carrier fluid while leaving the coating fluid deposited on the substrate as a coating layer.
3 more elements
A method of coating a substrate with a layer comprising the steps of:
- moving the substrate along a path through a coating station;
- forming a composite layer comprising at least one coating fluid and at least one carrier fluid having a formulation different from that of each coating fluid using carrier fluid that is immiscible with the coating fluid with which it forms an interface and wherein the carrier fluid has wetting properties that cause it to not wet the surface of the coating fluid-coated substrate;
- flowing the composite layer at a rate that is sufficient to form a continuous flowing fluid bridge of composite layer to the substrate for the coating width, wherein the carrier fluid portion of the composite layer is continuous;
- contacting the substrate with the flowing composite layer to interpose the coating layer between the substrate and the carrier fluid;
- and
- removing at least a portion of the carrier fluid while leaving the coating fluid deposited on the substrate as a coating layer;
- and
- depositing on the substrate the coating fluid at wet calipers between 50 and 10000 angstroms.
5 more elements
A method of coating a substrate with a layer comprising the steps of:
- moving the substrate along a path through a coating station;
- forming a composite layer comprising at least one coating fluid and at least one carrier fluid having a formulation different from that of each coating fluid;
- flowing the composite layer at a rate that is sufficient to form a continuous flowing fluid bridge of composite layer to the substrate for the coating width, wherein the carrier fluid portion of the composite layer is continuous;
- contacting the substrate with the flowing composite layer to interpose the coating layer between the substrate and the carrier fluid;
- and
- removing carrier fluid while leaving the coating fluid deposited on the substrate as a coating layer, wherein the removing the carrier fluid step comprises at least one of removing the carrier fluid without drying the carrier fluid and removing the carrier fluid without blowing off with a gas knife.
3 more elements
A method of coating a substrate with a layer comprising the steps of:
- moving the substrate along a path through a coating station;
- forming a composite layer comprising at least one coating fluid and at least one carrier fluid having a formulation different from that of each coating fluid;
- flowing the composite layer at a rate that is sufficient to form a continuous flowing fluid bridge of composite layer to the substrate for the coating width, wherein the carrier fluid portion of the composite layer is continuous;
- contacting the substrate with the flowing composite layer to interpose the coating layer between the substrate and the carrier fluid;
- and
- removing carrier fluid while leaving the coating fluid deposited on the substrate as a coating layer, wherein the removing the carrier fluid step comprises at least one of removing the carrier fluid after solidifying or gelling of the carrier fluid, and removing the carrier fluid after gelling, solidifying or chemically reacting the coating fluid.
3 more elements
An apparatus for coating a substrate with an ultra-thin layer comprising:
- a die for ejecting a carrier fluid;
- means for depositing at least one coating fluid onto the carrier fluid, wherein the carrier fluid has a formulation different from that of each coating fluid, and the carrier fluid is a liquid at the ambient condition at the coating station, to create a plurality of flowing layers of fluid in face-to-face contact with each other to form a composite layer;
- means for moving the substrate at a spaced distance from the die to permit the composite layer to form a continuous flowing fluid bridge to the substrate surface for the coating width and to deposit the coating layer on the substrate;
- and
- means for removing carrier fluid while leaving the coating fluid deposited on the substrate as a coating layer, wherein none of the components of the carrier fluid is part of the coating and at least a portion of all of any carrier fluid components are removed, thereby permitting the carrier fluid to act as a type of transfer device.
2 more elements
An apparatus for coating a substrate with an ultra-thin layer comprising:
- a die for electing a carrier fluid, wherein the die has a face, a slot communicating with the face, and a lip wherein the carrier fluid exits from the slot onto the face and flows along the face to the lip;
- means for depositing at least one coating fluid onto the carrier fluid, wherein the carrier fluid has a formulation different from that of each coating fluid to create a plurality of flowing layers of fluid in face-to-face contact with each other to form a composite layer;
- wherein the depositing means deposits the coating fluid onto the carrier fluid while the carrier fluid flows along the face, and wherein the composite layer is transported along the die face to the die lip;
- means for moving the substrate at a spaced distance from the die to permit the composite layer to form a continuous flowing fluid bridge to the substrate surface for the coating width and to deposit the coating layer on the substrate;
- and
- means for removing at least a portion of the carrier fluid while leaving the coating fluid deposited on the substrate as a coating layer;
- and
- a transfer surface on which the composite layer is deposited before being deposited on the substrate.
5 more elements
An apparatus for coating a substrate with an ultra-thin layer comprising:
- a die for electing a carrier fluid;
- means for depositing at least one coating fluid onto the carrier fluid, wherein the carrier fluid has a formulation different from that of each coating fluid to create a plurality of flowing layers of fluid in face-to-face contact with each other to form a composite layer;
- means for moving the substrate at a spaced distance from the die to permit the composite layer to form a continuous flowing fluid bridge to the substrate surface for the coating width and to deposit the coating layer on the substrate;
- and
- means for removing at least a portion of the carrier fluid while leaving the coating fluid deposited on the substrate as a coating layer comprising at least one of a doctor blade, blowing, means for applying centrifugal force, a suction device, draining by gravity, and pulling off by magnetic attraction.
2 more elements
An apparatus for coating a substrate with an ultra-thin layer comprising:
- a die for electing a carrier fluid;
- means for depositing at least one coating fluid onto the carrier fluid, wherein the carrier fluid has a formulation different from that of each coating fluid to create a plurality of flowing layers of fluid in face-to-face contact with each other to form a composite layer;
- means for moving the substrate at a spaced distance from the die to permit the composite layer to form a continuous flowing fluid bridge to the substrate surface for the coating width and to deposit the coating layer on the substrate;
- and
- means for removing carrier fluid while leaving the coating fluid deposited on the substrate as a coating layer wherein the means for removing carrier fluid comprises at least one of removing the carrier fluid without drying the carrier fluid and removing the carrier fluid without blowing off with a gas knife.
2 more elements
An apparatus for coating a substrate with an ultra-thin layer comprising:
- a die for ejecting a carrier fluid;
- means for depositing at least one coating fluid onto the carrier fluid, wherein the carrier fluid has a formulation different from that of each coating fluid to create a plurality of flowing layers of fluid in face-to-face contact with each other to form a composite layer;
- means for moving the substrate at a spaced distance from the die to permit the composite layer to form a continuous flowing fluid bridge to the substrate surface for the coating width and to deposit the coating layer on the substrate;
- and
- means for removing carrier fluid while leaving the coating fluid deposited on the substrate as a coating layer wherein the means for removing carrier fluid comprises at least one of removing the carrier fluid after solidifying or gelling of the carrier fluid, and removing the carrier fluid after gelling, solidifying or chemically reacting the coating fluid.
2 more elements
Dependencies are inferred from the claim text.