CN102665935A - 在基底上制备不均匀涂层的方法和装置 - Google Patents

在基底上制备不均匀涂层的方法和装置 Download PDF

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CN102665935A
CN102665935A CN2010800592396A CN201080059239A CN102665935A CN 102665935 A CN102665935 A CN 102665935A CN 2010800592396 A CN2010800592396 A CN 2010800592396A CN 201080059239 A CN201080059239 A CN 201080059239A CN 102665935 A CN102665935 A CN 102665935A
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加里·W·梅尔
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Abstract

辊式涂布机可通过添加向所述辊式涂布机在所述涂布辊的整个表面的分立位置提供涂布液体的一个或多个针管进行改造。所述针管从上游涂料池将局部涂层材料带提供到已经存在于所述涂布辊表面上的均匀涂层上，形成在均匀涂层上的条带图案。通过改变涂布机涂布辊的相对速度，所述条带的宽度也可被调节。

Description

在基底上制备不均匀涂层的方法和装置
背景技术
辊式涂布机通常被用于用各种各样的涂料涂布基底。辊式涂布机可通过使用实心涂布辊施加非常均匀的整体涂层，或通过使用带槽涂布辊施加不连续条纹状涂层。
发明内容
发明人确定对一些应用来讲在基底上具有一整体均匀的涂层并在所述均匀涂层的上面添加一不均匀涂层，如多个条带是期望的。此类涂层形式在生产可粘结附着、可重新定位的手写便签过程中施加水基、低附着性、背面涂胶涂层可能是有用的。由于单个可重新定位便签仅在便签的顶部具有粘合部分，仅在该分立区域需要防粘或低附着型涂层。这意味着条带涂层施加方法适于节约涂层成本和费用。
然而，所述附着涂层驻留在可重新定位的便签的书写面。条带涂层可能是视觉可见的，这取决于可重新定位便签的颜色，因为仅书写面的一部分是被涂布的。作为另外一种选择，不均匀书写表面可通过条带涂布形成。墨水进入纸张可能受存在或不存在低附着性涂层影响。因此，当采用可重新定位的便签时，条带涂层对于消费者来说可能是不能接受的。这意味着需要可用作低附着性涂层的具有足够厚度的整体涂层。
为了节约涂层材料费用，期望用整体低附着性涂层涂布可再定位的便签一个表面以确保视觉和书写变化不明显，并在需要足够的防粘涂层处带有条带涂层以保证每一个可再定位便签从便签层叠上可脱离。因此，具有均匀的薄第一涂层和在所述薄涂层上的第二条带涂层的不均匀涂层是期望的。这种情况相比在整个表面上施加均匀的较厚涂层能减少材料费用。
本发明人已经确定此类涂层可通过修改传统的辊式涂布机进行一步施加。以前，上述不均匀涂层在一辊式涂布机中需要两步工艺：首先，用涂布机中的实心辊施加均匀涂层；第二，通过用槽辊替换实体辊并使基底第二次通过所述涂布机施加所述条带图案涂层。采用一步工艺替代两步工艺显著降低了可再定位便签的工厂成本。
本发明人已经确定可通过在涂布辊的整个表面增加向辊式涂布机的分立位置提供涂布液体的一个或多个针管从而对常规辊式涂布机进行改造。所述针管从上游涂料池将局部涂层材料带提供到涂布辊上，添加在已经存在于所述涂布辊面上的均匀涂层上，形成在均匀涂层上的条带图案。通过改变涂布机涂布辊的相对速度，条带的宽度也可被控制，从而使宽度变成基于存在于可再定位便签上的粘合带所需要的宽度。作为另外一种选择，或与改变辊速一起，条带宽度也可通过改变涂层材料至针管的流动来改变。
因此，在一个实施例中，本发明在于一种用辊式涂布机涂布基底的方法，该方法包括：将第一涂层均匀地施加到涂布辊的面上；将第二涂层以一个或多个离散条带形式施加于所述第一涂层上；以及将所述第一和第二涂层转移到所述基底上。
在另一个实施例中，本发明在于一种涂布装置，该涂布装置包括涂布辊；用于将第一涂层施加到所述涂布辊的第一涂层施加器；和包括至少一个针管以用于将第二涂层施加到所述第一涂层上的第二涂层施加器。
附图说明
本领域技术人员将理解，本发明的讨论仅是针对示例性实施例的描述，其并不旨在限制本发明的更广泛的方面，其中更广泛的方面体现在示例性构造中。
图1为用于涂布基底的一种装置的透视图；
图2为纵向、用图1中的装置在一侧涂布有粘合剂条带及在另一侧涂布有不均匀低粘着性涂层的基底端视图；
图3为一种针筒组件的横截面图。
在说明书和附图中重复使用的标记旨在表示本发明相同或类似的部件或元件。
定义
本申请中，词语“包含”、“具有”和“包括”在法律上是具有等同含义的开放型术语。因此，除了列举的元件、功能、步骤或限制之外，还可以有其他未列举的元件、功能、步骤或限制。
具体实施方式
参照图1，其中示出了一种辊式涂布机10。示出的辊式涂布机包括五辊涂布机，然而将涂料溶液的离散条带施加到辊式涂布机中的施加辊表面上的方法适用于其它的辊式涂布机，如逆转辊涂布机、双辊涂布机、三辊涂布机和四辊涂布机。
图中所示的辊式涂布机包括第一涂层施加器12，其具有第一涂料供应器14。第一涂层施加器12将基本均匀的第一涂料15施加到辊W0的表面16上，并包括位于五辊涂布机中辊W0和辊W00之间的辊隙18中的涂料池17。第一涂料供应器14包括第一涂料罐20、第一涂料泵22和将第一涂料提供到涂料池的管道。可采用其它的第一涂层施加器12将基本上均匀的第一涂料15施加到涂布辊的表面16上，如封闭进料刮粉刀施加器或腔室刮粉刀施加器、刮粉刀和刮粉刀后面的涂料池、长槽型喷嘴、将所述涂布辊浸渍入涂料盘和喷注式涂布机。
在将均匀的第一涂料15施加到辊W0的表面16上后，使用第二涂层施加器26将第二涂料24以一个或多个离散条带施加到涂布辊上。第二涂层施加器26包括一个或多个流动连接到第二涂料供应器30的沿辊W0的表面位于整个机器上预定位置的一个或多个针管28。第二涂料供应器30可包括第二涂料罐32、第二涂料泵34以及将第二涂料24从第二涂料罐32抽出并送入歧管36的管道。针管28流动连接到歧管36。在施加第一涂料15后，可使用其它的第二涂料施加器26将第二涂料条带施加到辊表面上，如位于辊W0和辊W00之间辊隙中的带槽涂布辊。
现参见图3，包括压配入连接器40中的针管28的针管组件38以横截面形式示出。连接器40通常由尼龙或如不锈钢或黄铜的金属制成。连接器40具有六边形头部42，其具有带螺纹的圆柱主体44和穿过所述圆柱主体44钻的间隙孔。在六边形头部42中钻轻压配合孔，然后将具有合适直径和长度的针管28压配入六边形头部42中。然后，带有连接的针管28的连接器40可螺纹旋入歧管36中的螺纹孔中。由于连接器40可由塑料制成，并且在歧管36中采用较低的工作压力，通常，一旦针管组件38紧固到歧管36上，则不需要垫圈或密封件来防止泄漏。如果需要，针管可与其它类型的连接器使用，如快速拆卸连接器、扭锁连接器和卡套式连接器(bayonet coupler)。已知这些连接器用于将风管路或油管路提供给机器装置时。
理想地，针管28由制造成用来加工医疗注射器的不锈钢注射针管材制成。可采用其它管材且针管的横截面可为圆形、方形、三角形或其它几何形状。在一个实施例中，所述针管的横截面为圆形。针管的内径和针管的长度可基于施加的第二涂料24的流量、粘度以及所期望的第二涂料供应器30的工作压力进行选择。通常，所述针管的内径在约10密耳到约100密耳（0.25到2.54mm）之间，例如在约40密耳到约70密耳（1.02到1.78mm）之间。对针管内径的选择更多取决于要施加的第二涂料的量和粘度。并非所有连接至歧管的针管都需要具有相同的内径。因此，在整个纵向的不同位置有可能施加或多或少的第二涂料。
针管28的长度可调整成基于提供期望量的第二涂料所需的歧管压力而变化。通常，针管的长度在约2"到约8"（5.1到20.3cm）之间，例如在约3"到约7"（7.6到17.8cm）之间。期望针管具有足够的长度以在其中产生第二涂料的层流且从针管的出口处产生发散最少的液流。这种情形与例如由喷嘴产生的喷雾或液滴不同。液流可为施加涂料所需的连续液流或间歇（脉冲）液流。
可能需要较长的针管将第二涂料引导至两个涂布辊之间的辊隙中。这种情况与将第二涂料施加到涂布辊的表面上不同。虽然可使用其它压力，但通常，针管的尺寸加工成能够为从所述针管出来的第二涂料流提供在约5psi到约20psi(34.5到137.9千帕斯卡)之间的压力。随针管长度的增加以及第二涂料供应压力的增加，在整个机器上由每个针管散布的第二涂料的量的均匀性增加。
针管可被放置为将第二涂料流喷射到涂布辊的表面上。通常，这种喷射于第二涂料流喷射点处在与所述辊的表面的正切线成小于90度的角度下发生。通常，在针管的纵轴和于第二涂料流喷射点处所画所述辊的表面的正切线之间的喷射角在约0度到约60度之间。
作为另外一种选择，针管可被放置为在一涂布辊和另一个涂布辊之间的辊隙处喷射第二涂料流，例如在图1中所示的辊W0和辊W1之间的进料辊隙46处或在涂料池17上方的辊W1和辊W2之间的进料辊隙处喷射第二涂料流。通过从针管将第二涂料流导至进料辊隙中，第二涂料在涂布辊表面上的保持得到改善。
另外，有可能通过改变形成进料辊隙的涂布辊的相对速度来改变施加到基底的第二涂层的宽度。通常，为了使第二涂层宽度增加，辊W1的速度相对于辊W0的速度应减小。为了使第二涂层宽度减小，辊W1的速度相对于辊W0的速度应增加。使辊式涂布机中的下游辊的速度变慢倾向于使第二涂料的施加速度减小并使第二涂料在进料辊隙处铺展开来。与之相反，使辊式涂布机中的下游辊轴的速度变快倾向于使第二涂料的施加速度增大并减少第二涂料在进料辊隙处的铺展。有可能将辊W0放慢到使得自针管施加到基底的各个条带彼此合并从而在该基底上提供连续的第二涂层。
作为另外一种选择，或与改变涂布辊的速度一起，也可通过改变供给至针管的第二涂料溶液的量来改变第二涂层宽度。向针管供给较多的第二涂料溶液将使第二涂层宽度增加，而向针管供给较少的第二涂料溶液将使第二涂层宽度减小。
第一涂层施加器12和第二涂层施加器26可将相同的涂料溶液或不同的涂料溶液施加到辊式涂布机的辊上。对于一些实施例来说，可施加相同的涂料，且位于基底上的第一涂层15的量可以针对辊式涂布机的常规方式进行调整，而布置于基底上的第二涂层24的量可通过改变歧管36中的压力和针管28的尺寸进行改变。作为另外一种选择，具有相同的有效成分但不同固相百分比的类似涂料可由所述第一和第二涂层施加器（12、26）进行施加。例如，可由第一涂料供给器14供给低固相百分比的第一涂料以在整个基底上提供低基重的第一涂层15，由第二涂料供给器30供给高固相百分比的第二涂料以提供条带图案的高基重第二涂层24。
现参照图2，示出了基底的两个主表面都施加了涂层的基底46。在基底的第一主表面48上存在多个粘合剂条带50。所述粘合剂条带可位于沿基底宽度的位置上。在这些位置上，从基底上切割加工好的可重新定位的便签的顶边。在第二主表面52上存在非均匀涂层，该非均匀涂层通常为低粘着性涂层，如巯基官能硅树脂。所述非均匀涂层包括均匀施加到基本整个第二主表面52的第一涂层15和施加在所述第一涂层上的条带状非均匀第二涂层24。所述第二涂层通过针管28以条带状施加到基底46，该第二涂层通常在第一主表面48上的粘合剂条带的反面。通常，第二涂层24的宽度稍大于粘合剂条带50的宽度，这可由前述的在进料辊隙处的涂布辊的相对速度进行控制。
实例
本发明的对象和优点通过下面的非限制性实例进一步说明。这些实例中所提到的具体材料及其量以及其他条件和细节，均不应被解释为对本发明的不当限制。除非另外指明，否则实例以及说明书其余部分中的所有份数、百分数、比例等均按重量计。
在与图1相似的五辊涂布机上进行基底涂布以说明在如图3所示的纸基底的第二主表面上制造具有不均匀低附着性背面(LAB)涂层的涂布基底的一步辊轴涂布方法。用不均匀LAB涂层涂布葡萄色纸基底，因为这种涂布材料的条带在较暗颜色的纸上通常可见。以条带状图案将0.75克/平方英尺（gsf)的粘合剂涂布重量施加在该纸的第一主表面。所述粘合剂包含复合压敏微球粘合剂，所述复合压敏微球粘合剂含有如由Kesti等人提交的、名称为“Composite Pressure Sensitive AdhesiveMicrospheres”的美国专利号5,824,748中描述的完全在聚合物微球的边界内混合的两种或多种水不溶性聚合物。
所述LAB涂料含有20%可商购自日本Shin-Etsu Corporation、产品号为KF2001的巯基官能硅树脂固相的水溶液。在第二主表面上，在条带区域施加约0.020gsf的LAB涂层，而在无条带区域涂布约0.010gsf。为了实现这种涂层形式，五辊涂布机的辊W0以幅材速度的约5%、辊W1以幅材速度的约70-80%运行。改变辊W0的速度使得第一涂层LAB的涂层重量得以调整，而在第二涂层条带范围内的LAB涂层重量通过LAB流量（进料给针管的泵的速度）以及LAB条带宽度进行调整。调整辊W1速度使得由针管施加的LAB涂层适当铺展以实现LAB涂层宽度稍大于图2中所示的粘合剂条带宽度。
采用常规的转换方法将涂布好的纸基底转换成可重新定位的便签。注意到不均匀的LAB涂层图案没有在可重新定位便签的书写表面上形成可见的条带，因为LAB涂层覆盖了可重新定位便签的整个书写表面。还注意到所述可重新定位便签可从便签层叠上分离并可用作想要的用途而不会不当地粘结在一起。还检查了所述可重新定位便签的书写能力以确保在书写面上具有低LAB涂层重量和高LAB涂层重量的区域之间显示不出任何不同。没有观察到书写能力的任何不同。有关采用本发明的方法和装置制成的涂布基底的其它信息包含于2009年12月22日提交的、名称为“Adhesive Sheet With Differentially ThickRelease Coating”的美国临时专利申请号61/289186（律师档案号：65793US002）中。
在不脱离本发明的精神和范围的情况下，更具体地讲，在不脱离所附权利要求书中所示出的精神和范围的情况下，本领域技术人员可以采用本发明的其他修改形式和变型形式。应当理解，多种实施例的方面可以整体地或部分地与多种实施例的其他方面互换或结合。以上获得专利证书的专利申请中所有引证的参考文献、专利或专利申请的全部通过一致的方式以引证方式并入本申请。在并入的参考文献部分与本专利申请之间存在不一致或矛盾的情况下，应以前述具体实施方式中的信息为准。为了使本领域技术人员能够实施受权利要求书保护的本发明而给定的前述具体实施方式不应理解为是对本发明范围的限制，本发明的范围由权利要求书及其所有等同形式所限定。

Claims (20)

1.一种使用辊式涂布机涂布基底的方法，其包括：
将第一涂层均匀施加到涂布辊的表面；
将第二涂层以一个或多个离散条带形式施加在所述第一涂层上；以及
将所述第一和第二涂层转移到所述基底上。
2.根据权利要求1所述的方法，其中所述辊式涂布机包括五辊涂布机，所述基底包裹辊W3的至少一部分，并在所述辊W3和辊W2之间的进料辊隙处进入所述辊式涂布机，辊W1和所述辊W2形成辊隙，辊W0和所述辊W1形成辊隙，并且辊W00和所述辊W0轴形成辊隙。
3.根据权利要求2所述的方法，其中所述将第一涂层均匀施加到涂布辊的表面包括在所述辊W00和所述辊W0之间的进料辊隙处为涂料池提供第一涂料溶液。
4.根据权利要求2所述的方法，其中将所述第二涂层以一个或多个离散条带形式施加在所述第一涂层上包括为至少一个针管提供第二涂料，并将所述第二涂料喷射到所述辊W2、所述辊W1或所述辊W0的表面上。
5.根据权利要求4所述的方法，其中在所述针管的纵轴和喷射点处所述辊的表面的正切线之间的喷射角在约0度到约60度之间。
6.根据权利要求4所述的方法，其中所述第二涂料包括从所述至少一个针管出来的第二涂料流。
7.根据权利要求2所述的方法，其中将所述第二涂层以一个或多个离散条带形式施加在所述第一涂层上包括为至少一个针管提供第二涂料，且将所述第二涂料喷射到所述辊W2和所述辊W1之间或所述辊W1和所述辊W0之间的进料辊隙中。
8.根据权利要求7所述的方法，其中所述第二涂料包括从所述至少一个针管出来的第二涂料流。
9.根据权利要求7所述的方法，其中通过调整形成所述进料辊隙的辊之间的相对速度来改变所述一个或多个离散条带的宽度。
10.一种涂布装置，其包括：涂布辊；用于将第一涂层施加到所述涂布辊的第一涂层施加器；以及包括至少一个针管以用于将第二涂层施加到所述第一涂层上的第二涂层施加器。
11.根据权利要求10所述的涂布装置，其包括五辊涂布机。
12.根据权利要求11所述的涂布装置，其中所述第一涂层施加器包括在两个涂布辊之间的进料辊隙中的涂料池。
13.根据权利要求11所述的涂布装置，其中所述至少一个针管将所述第二涂料施加到进料辊隙。
14.根据权利要求11所述的涂布装置，其中所述至少一个针管将所述第二涂料施加到涂布辊的表面。
15.根据权利要求10所述的涂布装置，其中所述第二涂层施加器包括附接到歧管的至少两个针管。
16.根据权利要求15所述的涂布装置，其中所述歧管内的压力在5psi到20psi之间。
17.根据权利要求10所述的涂布装置，其中所述针管具有圆形横截面，且所述针管的内径在10到100密耳之间。
18.根据权利要求17所述的涂布装置，其中所述针管的长度在2到8英寸之间。
19.根据权利要求10所述的涂布装置，其中所述针管的长度在2到8英寸之间。
20.根据权利要求13所述的涂布装置，其包括用于改变形成所述进料辊隙的所述辊的相对速度的速度控制器。
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KR20120115332A (ko) 2012-10-17
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