Abstract: Methods and apparatuses for roll coating are provided. The roll coating system (100) includes a coating roll (110) having a deformable inner layer (12) with a surface thereof covered by a deformable outer layer (14), the inner layer being softer than the outer layer. A substrate (3) is conveyed to the nip (12) between the coating roll and a back-up roll (120). A metered coating material is transferred from the coating roll to a patterned surface structure (40) of the substrate at the nip to form a conformal coating on the patterned structure of the substrate.

Abstract: Methods and apparatuses for applying coatings on a moving web are provided. A coating die and a back-up roll engage with each other. The back-up roll includes a shell rotatably supported by a pressurized air layer. When a coating material is dispensed from the coating die onto the web to form a liquid coating, the pressure of the air layer is controlled such that the shell translates in space to balance forces from the air layer and the coating bead, while the web is being translated to drive the shell.

Abstract: A printing system (200) including a printing roll (220) is provided. The printing roll (220) includes an elastically deformable and compressible inner layer (224) and a thin outer shell (222) to cover the inner layer (224). The thin outer shell (222) includes a pattern of raised print features (223) to receive ink material thereon. The inner layer (224) is softer and thicker than the thin outer shell (222), and optionally, the thin outer shell (222) is removable from the inner layer (224). The inner layer (224) of the printing roll (220) has a thickness, a compression force deflection value and an elastically-deformable compressibility such that the raised print features (223) of the printing roll (220) do not slide or deform with respect to the printed web (2) in an amount to generate a substantially visible dot gain.

Abstract: Methods and apparatuses for applying coatings (9) on a moving web (3) are provided. A slot die (20) and a back-up roll (11) engage with each other. The back-up roll has a deformable inner layer (12) with a surface thereof covered by a deformable outer layer (14). The slot die and the flexible web at a contacting area are impressed into the back-up roll with an engagement depth D, which enables formation of a coating having a substantially uniform thickness.

Abstract: Methods and apparatuses for applying coatings on a moving web are provided. A slot die including a concave die lip coating surface and a back-up roll engage with each other. The back-up roll has a deformable inner layer with a surface thereof covered by a deformable outer layer. The slot die and the flexible web at a contacting area are impressed into the back-up roll with an engagement depth D, which enables formation of a coating having a substantially uniform thickness.

Abstract: Methods and apparatuses for applying coatings on a moving web are provided. A coating die and a back-up roll engage with each other. The back-up roll includes a shell rotatably supported by a pressurized air layer. When a coating material is dispensed from the coating die onto the web to form a liquid coating, the pressure of the air layer is controlled such that the shell translates in space to balance forces from the air layer and the coating bead, while the web is being translated to drive the shell.

Abstract: Methods and apparatuses for applying coatings on a baggy web are provided. A Mayer rod and a back-up roll engage with each other to form a nip. The back-up roll has a deformable inner layer with a surface thereof covered by a deformable outer layer. The Mayer rod and the flexible web at a contacting area are impressed into the back-up roll with a machine-direction nip width W and a nip engagement depth D, which enables formation of a coating having a substantially uniform thickness.

Abstract: A printing system (200) including a printing roll (220) is provided. The printing roll (220) includes an elastically deformable and compressible inner layer (224) and a thin outer shell (222) to cover the inner layer (224). The thin outer shell (222) includes a pattern of raised print features (223) to receive ink material thereon. The inner layer (224) is softer and thicker than the thin outer shell (222), and optionally, the thin outer shell (222) is removable from the inner layer (224). The inner layer (224) of the printing roll (220) has a thickness, a compression force deflection value and an elastically-deformable compressibility such that the raised print features (223) of the printing roll (220) do not slide or deform with respect to the printed web (2) in an amount to generate a substantially visible dot gain.

Abstract: A powder deagglomerator includes a vertical flow chamber, a powder inlet tube, and an ultrasonic horn vibrationally coupled to an ultrasonic transducer. The vertical flow chamber includes an outer wall, powder outlet port, and a mounting port sealably engaging an ultrasonic horn. The powder inlet tube extends through the outer wall and is aligned to dispense agglomerated powder in a gaseous stream downward onto a distal end of the ultrasonic horn. A method of using the powder deagglomerator to deagglomerate a powder is also disclosed.

Abstract: Methods and apparatuses for applying coatings (9) on a moving web (3) are provided. A slot die (20) and a back-up roll (11) engage with each other. The back-up roll has a deformable inner layer (12) with a surface thereof covered by a deformable outer layer (14). The slot die and the flexible web at a contacting area are impressed into the back-up roll with an engagement depth D, which enables formation of a coating having a substantially uniform thickness.

Abstract: A powder deagglomerator comprises a vertical flow chamber, a powder inlet tube, and an ultrasonic horn vibrationally coupled to an ultrasonic transducer. The vertical flow chamber includes an outer wall, powder outlet port, and a mounting port sealably engaging an ultrasonic horn. The powder inlet tube extends through the outer wall and is aligned to dispense agglomerated powder in a gaseous stream downward onto a distal end of the ultrasonic horn. A method of using the powder deagglomerator to deagglomerate a powder is also disclosed.

Abstract: Methods and apparatuses for applying coatings on a baggy web are provided. A Mayer rod and a back-up roll engage with each other to form a nip. The back-up roll has a deformable inner layer with a surface thereof covered by a deformable outer layer. The Mayer rod and the flexible web at a contacting area are impressed into the back-up roll with a machine-direction nip width W and a nip engagement depth D, which enables formation of a coating having a substantially uniform thickness.

Abstract: Methods and apparatuses for applying liquid coatings are provided. A first roll (14), a second roll (16), and a nip (146) formed between the first and second rolls are provided. A coating liquid (22) is supplied to the nip. The coating liquid is smoothed, via the nip, into a substantially uniform layer (22a) of liquid coating which is transferred to a substrate (12). The second roll (16) includes a thin metal shell (40) and a resilient layer (30), the thin metal shell encases the resilient layer therebeneath, and the thin metal shell is capable of deflecting in unison with the resilient layer such that the thin metal shell is elastically deformable at the nip when in contact with the first roll (14).

Abstract: Web handling apparatuses and methods are provided to passively control a lateral position of a moving web. The web wraps around support rollers adjacent opposed web edges. One or more guide rollers are positioned adjacent to the support rollers. The guide rollers are in rolling contact with the web edge to guide the moving, misguided web back into its desired lateral position.

Abstract: A powder-rubbing apparatus comprises: a rotatable rubbing roll having a rotational axis; a substrate path; an oscillating mechanism for oscillating the rotatable rubbing roll along the rotational axis; and a powder coating die comprising an inlet port in fluid communication with an outlet port disposed adjacent to the substrate path. The substrate frictionally contacts the rotatable rubbing roll within a rubbing zone. A dispenser for dispensing gas-borne powder is in fluid communication with the inlet port of the powder coating die. The dispenser is aligned such that at least a portion of a gas-borne powder dispensed from the powder coating die is deposited directly onto at least one of the rotatable rubbing roll or the substrate and conveyed into the rubbing zone. A method of using the powder-rubbing apparatus and a powder-rubbed web preparable thereby are also disclosed.

Abstract: A system and method for controlling curl in multi-layer webs. The method can include providing a coated web, curing the coating to form a multi-layer web, and stretching the web during curing of the coating. Some coatings shrink at least partially when cured such that curing the coating induces a strain in the multi-layer web. Stretching the web occurs during curing to induce an opposing strain that at least partially counteracts the strain induced by curing to form a multi-layer web having a desired curvature. The system can include a curing section configured to cure the coating, and can further include a web stretching section, which can be located proximate the curing section and can be substantially coincident with the curing section, such that the web is stretched while the coating is cured.

Abstract: A method is provided. The method may include engaging a first edge region on a first surface of a substrate with a first support roller; engaging a second edge region on the first surface of the substrate with a second support roller; transporting the substrate over the first and the second support rollers; repeating the following sequence of steps to form a thin film on the substrate: (a) exposing the substrate to a first precursor; (b) supplying a reactive species to the substrate after exposing the substrate to the first precursor; and depositing a vapor on the thin film to form a coating on the thin film.

Abstract: An apparatus for steering a web, including a web path having at least one steering roller and an exit roller, each having a mount; wherein the steering roller(s) each have an axis of rotation and wherein the mounts for the steering roller(s) can pivot those axes with a total of two degrees of freedom. An array comprising a plurality of sensors for monitoring the position of the web is present connected to a controller so as to determine the position and angular orientation of the web. The controller adjusts the pivot(s) of the mount(s) so as to control the angular orientation and the lateral position of the web at a particular point along the web path.

Abstract: A web path for conveying a web material includes at least two support rollers contacting a single major surface of the web material, wherein the web material is of indefinite length and has a first and a second edge. A first support roller contacts a first edge region of the web material, and a second support roller contacts a second edge region of the web material such that the web material has a substantial un-contacted region between the first and the second support roller including at least about 50% of the width of the web material. At least one of the first support roller and the second support roller are supported on a bowed shaft such that at least one of the first and second support rollers is angled with respect to the direction of motion of the web.

Abstract: A manufacturing system includes a sensing system that provides high-resolution feedback for web guiding and tension control. The system may be especially useful for web material that is manufactured to include micro-replicated structures with micron size scale. A micro-replication station forms a pattern of micro-replicated lenses on a web material. The sensing system illuminates a measurement area on the web material and detects an angular distribution of light exiting a set of the micro-replicated lenses within the first measurement area. A control system that adjusts at least one process control parameter of the transport system based on the detected angular distribution.