System and method for using a force model to control process configurations for the encapsulation of a web

An encapsulating system, comprising:

• at least one blade configured to cause an encapsulation material to encapsulate a web;
• at least one roller for supporting and encouraging the web to pass the blade;
• a force model module configured to receive characteristics of the web and the encapsulation material, wherein the force model module is configured to generate operating parameters for controlling the blade and the roller based on the received characteristics;
• and
• a control module configured to implement the generated operating parameters such that a specific force is exerted on the web by the blade, wherein the operating parameters comprise one or more parameters selected from the group consisting of a first entrance angle of a first blade, a first exit angle of the first blade, a first radius of the first blade, a second entrance angle of a second blade, a second exit angle of the second blade, a second radius of the second blade, and tension of the web and
• wherein the force modeling module generates the operating parameters based on a force equation defined as:
• F
• N
• ⁢
• ⁢
• 2
• F
• N
• ⁢
• ⁢
• 1
• =
• Cos
• ⁢
• ⁢
• θ
• i
• ⁢
• ⁢
• 2
• Cos
• ⁢
• ⁢
• θ
• i
• ⁢
• ⁢
• 1
• ⁡
• (
• 1
• -
• Cos
• ⁢
• ⁢
• θ
• e
• ⁢
• ⁢
• 1
• ⁢
• μ
• )
• ⁢
• (
• 1
• -
• Cos
• ⁢
• ⁢
• θ
• i
• ⁢
• ⁢
• 2
• ⁢
• μ
• )
• wherein FN2 is a force normal to the web at the second blade, FN1 is a force normal to the web at the first blade, θi1 is the first entrance angle, θe1 is the first exit angle, θi2 is the second entrance angle, θe2 is the second exit angle, and μ is a coefficient of friction between the web and the blades.