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: Wet-on-wet coating processes are provided to produce multilayer articles. First and second coating materials are sequentially applied on to a structured substrate surface to form a skin layer directly over the structured substrate surface and a bulk layer over the skin layer. The conformability of the skin layer can be adjusted to provide desired surface and bulk properties.

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: Wet-on-wet coating processes are provided to produce multilayer articles. First and second coating materials are sequentially applied on to a structured substrate surface to form a skin layer directly over the structured substrate surface and a bulk layer over the skin layer. The conformability of the skin layer can be adjusted to provide desired surface and bulk properties.

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: Optical films for redirecting light are described, and optical systems, such as display systems, incorporating such optical films are described. The optical film may include a first structured surface including a plurality of prismatic structures, and a second structured surface opposing the first structured surface and including a plurality of microstructures. An effective transmission of the optical film is not more than 1% less than a film with a comparable construction except for a smooth, non-structured second surface.

Abstract: Optical films for redirecting light are described, and optical systems, such as display systems, incorporating such optical films are described. The optical film may include a first structured surface including a plurality of prismatic structures, and a second structured surface opposing the first structured surface and including a plurality of microstructures. An effective transmission of the optical film is not more than 1% less than a film with a comparable construction except for a smooth, non-structured second surface.

Abstract: An optical film having a structured surface is described. At least 90% of the structured surface has a slope magnitude that is less than about 5 degrees. The optical film may have an optical haze of less than about 10% and an optical clarity of less than about 50%, or may have an optical haze of less than about 7.5% and an optical clarity of less than about 60%, or may have an optical haze of less than about 3% and an optical clarity of less than about 65%.

Abstract: Articles with thin caliper melt coatings of high molecular weight, high viscosity materials and methods of making such coatings.

Abstract: A method of controlling a slot die comprises, while continuing to pass the extrudate through the fluid flow path and out the applicator slot, changing the position of the actuators with the controller to either increase the cross-directional thickness of the fluid flow path adjacent each of the actuators or substantially close the fluid flow path adjacent the actuators, and after changing the cross-directional thickness of the fluid flow path adjacent each of the actuators, while continuing to pass the extrudate through the fluid flow path and out the applicator slot, repositioning each of the actuators with the controller according to the set of discrete settings to resume operating the slot die with the actuators positioned according to the set of discrete settings.

Abstract: A system comprises a slot die including an applicator slot extending about a width of the slot die, wherein the applicator slot is in fluid communication with a fluid flow path through the slot die, and a plurality of actuators spaced about the width of the slot die, wherein each actuator in the plurality of actuators is operable to adjust a cross-directional thickness of the fluid flow path at its respective location to provide a local adjustment of fluid flow through the applicator slot. The system further comprises a controller configured to set the position of each actuator according to one of a plurality of discrete settings for operation of the slot die. The controller is further configured to, using fluid dynamics and a digital model of the die, predict a set of discrete settings from the plurality of discrete settings corresponding to a preselected cross-web profile for the extrudate.

Abstract: A method of controlling a slot die comprises positioning actuators of the slot die with a controller according to a first set of discrete settings, operating the slot die by passing an extrudate through the fluid flow path and out the applicator slot with the actuators positioned according to the first set of discrete settings, and while passing the extrudate through the fluid flow path and out the applicator slot, changing the positions of the actuators with the controller to create patterned features in the extrudate.

Abstract: A method of controlling a slot die comprises, while continuing to pass the extrudate through the fluid flow path and out the applicator slot, changing the position of the actuators with the controller to either increase the cross-directional thickness of the fluid flow path adjacent each of the actuators or substantially close the fluid flow path adjacent the actuators, and after changing the cross-directional thickness of the fluid flow path adjacent each of the actuators, while continuing to pass the extrudate through the fluid flow path and out the applicator slot, repositioning each of the actuators with the controller according to the set of discrete settings to resume operating the slot die with the actuators positioned according to the set of discrete settings.

Abstract: A method of controlling a slot die comprises, while continuing to pass the extrudate through the fluid flow path and out the applicator slot, changing the position of the actuators with the controller to either increase the cross-directional thickness of the fluid flow path adjacent each of the actuators or substantially close the fluid flow path adjacent the actuators, and after changing the cross-directional thickness of the fluid flow path adjacent each of the actuators, while continuing to pass the extrudate through the fluid flow path and out the applicator slot, repositioning each of the actuators with the controller according to the set of discrete settings to resume operating the slot die with the actuators positioned according to the set of discrete settings.

Abstract: Articles with thin caliper melt coatings of high molecular weight, high viscosity materials and methods of making such coatings.

Abstract: This disclosure provides (meth)acryloyl pressure-sensitive adhesive foams and foam articles having one or more of the following properties: small cells, uniform cell sizes, pressure sensitive adhesive compositions, compliance to irregular substrates and vibration damping, and shock absorbing properties.

Abstract: Optical films for redirecting light are described, and optical systems, such as display systems, incorporating such optical films are described.

Abstract: Computer implemented method for making a die includes: selecting coating uniformity required to produce a particular coated product with the die and a value for one or more dimensions of the die; determining (using a mathematical model determined by regression analysis) total indicated run-out (TIR) of a die surface and dimensions of the die not having a user specified value; and machining die part or parts to the determined TIR and dimensions. A thermal treatment process for reducing the number of finishing (e.g., grinding) cycles needed to produce a desired die flatness is provided. A coating fluid rheological characteristic can be an input to the method.

Abstract: A method of controlling a slot die comprises positioning actuators of the slot die with a controller according to a first set of discrete settings, operating the slot die by passing an extrudate through the fluid flow path and out the applicator slot with the actuators positioned according to the first set of discrete settings, and while passing the extrudate through the fluid flow path and out the applicator slot, changing the positions of the actuators with the controller to create patterned features in the extrudate.