Coating system with multiple dispensing needles

A system for applying a coating material onto a substrate, comprising:

• a back-up roll nipped with a reverse roll;
• a distribution manifold having a cavity and a plurality of needle tubes in fluid communication with the cavity, the plurality of needle tubes each having a needle tip dispensing a coating material towards the nip between the back-up roll and the reverse roll;
• an offset roll nipped with the back-up roll creating a web path moving the substrate through the nip between the back-up roll and the offset roll;
• and
• a flow control apparatus metering a flow of the coating material from the needle tubes at a predetermined rate,
• wherein the distribution manifold separates into a manifold containing the cavity, and a removable cartridge having the plurality of needle tubes, the removable cartridge is releasably held against the manifold at a manifold mating surface of the manifold, a clamping mechanism is configured to secure the removable cartridge to the manifold mating surface, and the plurality of needle tubes extend from the removable cartridge in a direction generally parallel to the manifold mating surface of the manifold.

A method of applying, via a system, a coating material onto a substrate, the system comprising:

• a contacting element, the substrate being conveyed past the contacting element;
• a distribution manifold having a cavity and a plurality of needle tubes in fluid communication with the cavity, the plurality of needle tubes each having a needle tip dispensing a coating material towards a point of contact between the substrate and the contacting element;
• and
• a flow control apparatus metering a flow of the coating material from the needle tubes at a predetermined rate,
• wherein the distribution manifold separates into a manifold containing the cavity, and a removable cartridge having the plurality of needle tubes, the removable cartridge is releasably held against the manifold at a manifold mating surface of the manifold, a clamping mechanism is configured to secure the removable cartridge to the manifold mating surface, and the plurality of needle tubes extend from the removable cartridge in a direction generally parallel to the manifold mating surface of the manifold,
• the method comprising:
• conveying the substrate past the contacting element;
• and
• dispensing the coating material from the needle tubes at a predetermined rate, said rate being less than or equal to a maximum rate that the interaction between the substrate and the contacting element would permit to pass the point of contact.