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 (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 (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: An idler roller having a fixed shaft with at least one spherical bearing and a second bearing which may, but need not be, a spherical bearing. In some embodiments, the second bearing is slidably-mounted on a central shaft. A shell is mounted between these bearings. Any changes in dimensions resulting from changes in temperature may them be accommodated by sliding movement of the second bearing, sparing the shell from distortion by bending or buckling. In other exemplary embodiments, the spherical bearing includes a first housing element fixedly-mounted on a central shaft and a complementary first free element disposed against the first housing element. A second bearing element is mounted on the central shaft, and a shell is attached to the first free element and rotatably-mounted to a second bearing element with a biasing element mounted on the central shaft urging a second free element away from the first free element.

Abstract: An ion-conductive membrane that includes a first layer comprising a first ionomer, and a porous polymer substrate, where at least a portion of the first ionomer is interpenetrated within the porous polymer substrate by ionomer-induced phase separation.

Abstract: A method for forming a microporous membrane having a microstructure is described. Dope and coagulant formulations are simultaneously cast, where the coagulant formulation diffuses into the dope formulation through an interface effecting a phase inversion forming a microstructure.

Abstract: A system for forming a multi-layer film, where the system includes a backing support having a surface and a close-coupled unit configured to be disposed adjacent the surface of the backing support. The close-coupled unit includes a corona electrode and a coating die disposed at a downstream location along the surface from the corona electrode.

Abstract: The disclosure relates to a method for forming a die having an applicator slot for translating an applicator liquid through the die. The slot is in fluid communication with a die cavity. An expansible chamber device is disposed within the die cavity and changes volume in response to changes in fluid pressure within the expansible chamber device, which may be regulated by a means for controlling the volume of the expansible chamber device. In some embodiments, the die has a single rectangular applicator slot, and the expansible chamber device is an expandable cylindrical tube disposed within the die cavity. In other embodiments, the fluid within the expansible chamber device may be selected to be a compressible gas. In further embodiments, the fluid within the expansible chamber device may be selected to be an incompressible liquid.

Abstract: A die assembly includes a die housing having a multiplicity of inner wall sections defining a die cavity, an inlet passageway passing through the die housing in fluid communication with the die cavity, and an outlet passageway passing through the die housing in fluid communication with the die cavity at a position distal from the inlet passageway. The die assembly also includes an insert removably received in the die cavity. The insert includes a body portion having a multiplicity of outer wall sections, and at least one flow channel is formed between at least one inner wall section of the die housing and each opposite outer wall section of the body portion of the insert; fluid communicates between the external supply and each of the flow channels and the outlet passageway. Also provided is a die insert and a method of purging gas from a die having an insert.

Abstract: An ion-conductive membrane that includes a first layer comprising a first ionomer, and a porous polymer substrate, where at least a portion of the first ionomer is interpenetrated within the porous polymer substrate by ionomer-induced phase separation.

Abstract: The disclosure relates to an apparatus including a die having at least one applicator slot for translating an applicator liquid through the die. The slot is in flow communication with a die cavity. An expansible chamber device is disposed within the die cavity and changes volume in response to changes in fluid pressure within the expansible chamber device, which may be regulated by a means for controlling the volume of the expansible chamber device. The applicator liquid is translated through the die and delivered from the applicator slot at intervals corresponding to actuation of the expansible chamber device. In some embodiments, the die has a single rectangular applicator slot, and the expansible chamber device is an expandable cylindrical tube disposed within the die cavity. In other embodiments, the fluid within the expansible chamber device is an incompressible liquid.

Abstract: A method for forming a microporous membrane having a microstructure is described. Dope and coagulant formulations are simultaneously cast, where the coagulant formulation diffuses into the dope formulation through an interface effecting a phase inversion forming a microstructure.

Abstract: An apparatus comprising a die having at least one application slot. The slot is in fluid communication with a die cavity. An expansible chamber device is disposed within the die cavity and changes volume in response to changes in pressure within the expansible chamber device. Another aspect of the invention is a method of translating a liquid through a die. A coating die is provided. The die comprises at least one applicator slot in fluid communication with a die cavity. An expansible chamber device is disposed within the cavity. The expansible chamber device is actuated by changes in the fluid pressure within the expansible chamber device. The liquid is translated through the die and delivered from the application slot at intervals corresponding to actuation of the expansible chamber device. Another aspect of the invention is a method for forming a die. An apparatus comprising a die having at least one applicator slot in fluid communication with the die cavity is provided.

Abstract: The disclosure relates to a die assembly. The die assembly includes a die housing having a plurality of inner wall sections defining a die cavity, an inlet passageway passing through the die housing in fluid communication with the die cavity, and an outlet passageway passing through the die housing in fluid communication with the die cavity at a position distal from the inlet passageway. The die assembly also includes an insert removably received in the die cavity. The insert includes a body portion having a plurality of outer wall sections, and at least one flow channel is formed between at least one inner wall section of the die housing and each opposite outer wall section of the body portion of the insert. The die assembly includes a means for providing fluid communication between the external supply of fluent material and each of the at least one flow channel and the outlet passageway.

Abstract: An apparatus comprising a die having at least one application slot. The slot is in fluid communication with a die cavity. An expansible chamber device is disposed within the die cavity and changes volume in response to changes in pressure within the expansible chamber device. Another aspect of the invention is a method of translating a liquid through a die. A coating die is provided. The die comprises at least one applicator slot in fluid communication with a die cavity. An expansible chamber device is disposed within the cavity. The expansible chamber device is actuated by changes in the fluid pressure within the expansible chamber device. The liquid is translated through the die and delivered from the application slot at intervals corresponding to actuation of the expansible chamber device. Another aspect of the invention is a method for forming a die. An apparatus comprising a die having at least one applicator slot in fluid communication with the die cavity is provided.

Abstract: An adjustable mounting system for premetered contact coating dies includes a base and a die-receiving portion movably connected to the base. During coating, the die can float a distance from the surface being coated based on the balance of forces between the die and the coated surface. This creates a variable separation gap and allows automatic self-compensating for variations in web or fluid properties. This, in turn, optimizes the coating characteristics. The mounting system can also include an enclosure for protecting its components.

Abstract: A method for making a flexible carrier tape for storage and delivery of electronic components by an advancement mechanism is disclosed. The tape includes a strip portion having a top surface, a bottom surface opposite the top surface, and a device for engagingly receiving the advancement mechanism; and a plurality of aligned pockets for carrying the electronic components. The pockets are spaced along the strip portion and opening through the top surface. The device for engagingly receiving the advancement mechanism includes a plurality of hollow protuberances that are spaced equally along the strip portion, open through the strip portion, and extend outwardly from the strip portion. The protuberances are adapted to receive the advancement mechanism within the hollow portion. The method includes simultaneously thermoforming the pockets and the protuberances to provide excellent registration therebetween.

Abstract: A flexible carrier tape for storage and delivery of electronic components by an advancement mechanism comprises: (a) a strip portion having a top surface, a bottom surface opposite the top surface, and means for engagingly receiving the advancement mechanism; and (b) a plurality of aligned pockets for carrying the electronic components. The pockets are spaced along the strip portion and open through the top surface. The means for engagingly receiving the advancement mechanism comprises a plurality of hollow protuberances that are spaced equally along the strip portion, open through the strip portion, and extend outwardly from the strip portion. The protuberances are adapted to receive the advancement mechanism within the hollow portion. Methods for manufacturing such carrier tapes are also disclosed.