Abstract: Methods and apparatuses for masking the edges of a substrate when performing direct or reverse gravure coating using a kiss-coat configuration, particularly useful for in-line coating of biaxially oriented polymeric films. The methods and apparatuses include a masking plate configured to prevent the edge of a portion of a substrate from contacting a gravure roll, the masking plate includes a top portion having a Rockwell B hardness equal to or greater than 80, and a thickness of between 0.03125 inches and 0.375 inches. This masking plate prevents build-up of coating on the edges of the substrate which otherwise can cause film orientation production instabilities such as film breaks, sticking to tenter clips, and/or edge trim recycling incompatibilities. The masking plate provides a masking method that is effective and durable, minimizing production downtime and maintenance.

Abstract: Described are heat sealable and metallized multi-layer biaxially oriented polypropylene films and methods of making these films. The films and methods include a novel sealant composition having a polymeric coupling agent, which is used to form strong chemical linkages between anti-blocking agent (ABA) particles and the polymer matrix. The polymeric coupling agents enhance the nucleating efficiency of ABA particles and co-crystallize with polymer chain segments surrounding the ABA particles. Polymeric films with coextruded sealant layers can be made with improved morphology, thermal behavior, and dynamic rheological properties which can be easily released without sticking to cooling or casting drums at high film-making production speeds.

Abstract: Methods and apparatuses for masking the edges of a substrate when performing direct or reverse gravure coating using a kiss-coat configuration, particularly useful for in-line coating of biaxially oriented polymeric films. The methods and apparatuses include a masking plate configured to prevent the edge of a portion of a substrate from contacting a gravure roll, the masking plate includes a top portion having a Rockwell B hardness equal to or greater than 80, and a thickness of between 0.03125 inches and 0.375 inches. This masking plate prevents build-up of coating on the edges of the substrate which otherwise can cause film orientation production instabilities such as film breaks, sticking to tenter clips, and/or edge trim recycling incompatibilities. The masking plate provides a masking method that is effective and durable, minimizing production downtime and maintenance.

Abstract: Methods and equipment to reduce or eliminate metal edge-pick-off defects in freshly metallized polymeric film rolls are disclosed. The method may include the formation of a “raised edge” such that the ingress of air and/or oxygen gas into the ends of the wound freshly-metallized roll is blocked or impeded, thus reducing oxidation of the metal. This method significantly reduces the amount of metal pick-off defects and resulting quality and productivity losses due to scrapping of such defective metallized film.