Non-orthogonal coater geometry for improved coatings on a substrate

A method of applying a coating over a surface of a substrate, comprising:

• providing a coating zone along a path of travel, wherein a start of the coating zone along the path of travel is defined as Position A and an end of the coating zone along the path of travel is defined as the coating ending position, and the path of travel between the Position A and the coating ending position is along a straight line defined as the substrate path of travel;
• dispensing coating vapors from a location adjacent to the Position A toward the coating zone, wherein the coating vapors are dispensed toward the coating zone by moving the coating vapors through a slit opening of a coating nozzle, wherein the coating vapors dispensed through the slit opening of the coating nozzle along a vertical plane passing from longitudinal axis of the coating nozzle toward the coating zone, wherein the vertical plane is normal to the surface of the substrate passing through the coating zone and in facing relationship to the coating nozzle defined as the surface of the substrate be coated, wherein an imaginary straight line is normal to the vertical plane extends from the vertical plane in a downstream direction along the substrate path of travel, and the imaginary line and the substrate path of travel subtend an angle in the range of greater than zero to less than 90 degrees, wherein an open end of the angle formed by the imaginary line and the substrate path of travel faces the upstream direction of the substrate path of travel, and
• moving the substrate along the substrate path of travel from the Position A toward the coating ending position with the surface of the substrate to be coated facing the coating vapors to apply a coating to the surface of the substrate to be coated.