EP0000241B1 - Procédé et dispositif pour enduire une bande - Google Patents

Procédé et dispositif pour enduire une bande Download PDF

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Publication number
EP0000241B1
EP0000241B1 EP78300013A EP78300013A EP0000241B1 EP 0000241 B1 EP0000241 B1 EP 0000241B1 EP 78300013 A EP78300013 A EP 78300013A EP 78300013 A EP78300013 A EP 78300013A EP 0000241 B1 EP0000241 B1 EP 0000241B1
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EP
European Patent Office
Prior art keywords
web
applicator roll
roll
coating
coating medium
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
EP78300013A
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German (de)
English (en)
Other versions
EP0000241A1 (fr
Inventor
Aubrey Frank Riggs
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Imperial Chemical Industries Ltd
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Imperial Chemical Industries Ltd
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Filing date
Publication date
Application filed by Imperial Chemical Industries Ltd filed Critical Imperial Chemical Industries Ltd
Publication of EP0000241A1 publication Critical patent/EP0000241A1/fr
Application granted granted Critical
Publication of EP0000241B1 publication Critical patent/EP0000241B1/fr
Expired legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/28—Processes for applying liquids or other fluent materials performed by transfer from the surfaces of elements carrying the liquid or other fluent material, e.g. brushes, pads, rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C1/00—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
    • B05C1/04—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length
    • B05C1/08—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line
    • B05C1/0821—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line characterised by driving means for rollers or work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C1/00—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
    • B05C1/04—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length
    • B05C1/08—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line
    • B05C1/0826—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line the work being a web or sheets
    • B05C1/083—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line the work being a web or sheets being passed between the coating roller and one or more backing rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C1/00—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
    • B05C1/04—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length
    • B05C1/08—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line
    • B05C1/0839—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line the work being unsupported at the line of contact between the coating roller and the work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C1/00—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
    • B05C1/04—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length
    • B05C1/08—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line
    • B05C1/0856—Reverse coating rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C1/00—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
    • B05C1/04—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length
    • B05C1/08—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line
    • B05C1/12—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line the work being fed round the roller
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C1/00—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating
    • B05C1/04—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length
    • B05C1/08—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line
    • B05C1/0826—Apparatus in which liquid or other fluent material is applied to the surface of the work by contact with a member carrying the liquid or other fluent material, e.g. a porous member loaded with a liquid to be applied as a coating for applying liquid or other fluent material to work of indefinite length using a roller or other rotating member which contacts the work along a generating line the work being a web or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C9/00—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important
    • B05C9/04—Apparatus or plant for applying liquid or other fluent material to surfaces by means not covered by any preceding group, or in which the means of applying the liquid or other fluent material is not important for applying liquid or other fluent material to opposite sides of the work

Definitions

  • This invention relates to a method and apparatus for coating a web, and, in particular, to a method of applying a coating to at least one surface of a web by a reverse roll technique.
  • a web is considered to be any material in laminar form capable of being fed from a roll or other source of supply, subjected to a process treatment, and subsequently rewound in roll- form, or cut into sheets or otherwise converted for use by a consumer.
  • Typical webs include paper, and plastics films.
  • coating is used throughout this specification to describe both the process of depositing a liquid or flowable material, including printing inks, in a controlled manner on to a surface of a moving web, and the layer of material so deposited on that surface either in the wet state or in a subsequently dried condition.
  • a principle of the reverse roll technique is that the supply of coating medium to the applicator roll. surface should be controlled by mechanical metering means, such as a flexible doctor blade or an associated doctor roll cooperating with the applicator roll, to ensure that the requisite volume of coating medium is entrained on the applicator roll surface and thence deposited on the web surface.
  • mechanical metering means such as a flexible doctor blade or an associated doctor roll cooperating with the applicator roll
  • the coating medium to dry out and form crusts on the mechanical metering means, for example on the edge of the doctor blade, or for particles of grit or other contaminants to accumulate on the doctoring device, with consequent disruption of coating uniformity.
  • Reciprocation of the metering means parallel to the axis of the applicator roll has therefore been proposed to overcome this problem, but serves simply to randomize the distribution of coating defects on the web surface rather than achieving elimination of these defects.
  • a further principle of the conventional reverse roll coating technique is that the web should be partially wrapped around the resilient surface of a support or backing roll which rotates in the direction of movement of the web and cooperates with the applicator roll to define a "nip" through which the web passes.
  • the web makes only line contact with the surface of the applicator roll and consistently uniform coating behaviour is difficult to achieve.
  • a still further principle of the reverse roll technique is that the deposited coating medium should be wiped onto the web surface by the applicator roll to assist the production of a smooth coating on the web.
  • the applicator roll is therefore usually rotated at a peripheral speed at least equal to, and preferably exceeding, the linear speed of the travelling web, the latter seldom exceeding 700 feet/minute (3.5 ms-1).
  • the wipe ratio which is the ratio of the speed of the applicator roll to that of the web, is conventionally within a range of from 1:1 to 3:1.
  • transverse ridges or "chatter” marks resulting from vibration of the web and applicator roll, appear in the applied coating.
  • the necessarily high roll speed results in increased wear and diminished life of the bearings in which the applicator roll is rotatably mounted.
  • a typical prior art reverse roll coating technique is disclosed in British patent 1 151 690 which relates to an apparatus and method for depositing a water base coating composition on to an endless web of paper by a three-roll coating including an applicator roll, a pick up roll and a metering roll, by receiving an excess amount of coating material onto the peripheral surface of the pick up roll, transferring coating material therefrom to the peripheral surface of a cooperating applicator roll, metering and smoothing the transferred layer of coating material by shear and engaging the smoothed and metered layer of coating material on the applicator roll with the web of paper travelling in the opposite direction to transfer coating material from the applicator roll to the web of paper.
  • British patent 1 151 690 therefore requires mechanical metering means such as a metering roll cooperating with the applicator roll accurately to meter the amount of coating medium retained on the applicator roll. Further mechanical metering means, such as an air knife are subsequently required to cut off excess coating material from the surface of the coated paper web.
  • the present invention provides a method of coating a surface of a web comprising forwarding the web in contact with the surface of an applicator roll, supplying a flowable coating medium to the surface of the applicator roll, and rotating the applicator roll in a direction contrary to the direction of forward movement of the web at a peripheral velocity less than the forward speed of the web, characterised by the absence of means cooperating with the applicator roll surface for metering coating medium thereon, and in that the dynamic viscosity of the coating medium and the peripheral velocity of the applicator roll are each selected in accordance with the relationship such that a layer of coating medium of equilibrium thickness not exceeding 5.0 mm is entrained on the surface of the applicator roll for transfer to the surface of the web, and the ratio of the peripheral velocity of the applicator roll to the forward speed of the web is maintained at a value not exceeding 0.4:1, wherein
  • the invention also provides an apparatus for applying a liquid coating medium to a surface of a travelling web comprising an applicator roll rotatable in a direction contrary to the direction of travel of the web, a reservoir for supplying liquid coating medium to the surface of the applicator roll, and means for forwarding the web in contact with the surface of the applicator roll characterised by guide means for maintaining the web in engagement with the surface of the applicator roll over an arc contact angle of from 5 to 90°, by the absence of means cooperating with the applicator roll surface for metering coating medium thereon, and by means for rotating the applicator roll counter to the direction of travel of the web at a peripheral velocity not exceeding 0.4 of the forward speed of the web such that, in the absence of said metering means, a uniform layer of coating medium having an equilibrium thickness not exceeding 5.0 mm can be entrained from the reservoir onto the surface of the applicator roll for transfer to the web surface.
  • the applicator roll which may be in the form of a solid bar, or, preferably, a hollow tube with provision for circulation therethrough of a coolant medium such as chilled water, is suitably formed from mild steel, the surface of the roll being sufficiently smooth to ensure the deposition of a uniform coating on the web.
  • the surface of the roll is chromium plated and polished to a suitable degree of smoothness - for example, a surface texture with an Arithmetical Mean Deviation, Ra, (commonly referred to as Centre Line Average surface roughness) according to British Standard 1134 of 1972 of from 0.2 to 0.05,um (8 to 2 microinches), and preferably about 0.1 pm (4 microinches).
  • the applicator roll is positioned with its rotational axis substantially normal to, and parallel to the plane of, the direction of movement of the travelling web, provision being made, if desired, for varying the roll position relative to the web to achieve the required degree of coating uniformity.
  • the axial length of the roll is such that the roll projects beyond each longitudinal edge of the web so that the entire surface of the web may be coated, and in the case of wide webs, for example of the order of 48 inches (1.2 m), the rigidity of the roll may be improved, if desired, by the provision between the ends of the roll of at least one intermediate supporting member, such as a semi-cylindrical shell bearing, cooperating with the roll surface.
  • the supporting member comprises a self-lubricating bearing surface of a material such as the 'Fluon' brand.of polytetrafluoroethylene, 'Fluon' being a registered Trade Mark of Imperial Chemical Industries Limited.
  • the continuous transfer to the web surface of the requisite amount of coating medium depends, inter alia, on the viscosity characteristics of the medium and on the geometry of the applicator assembly.
  • Particularly satisfactory coating behaviour has been observed with an applicator roll of relatively small diameter compared to that employed in conventional reverse roll coating equipment, and it is therefore preferred that the diameter of the applicator roll should be within a range of from 25 to 102 mm, preferably about 50 mm.
  • the applicator roll rotates in a direction contrary to the direction of movement of the travelling web, and by adjusting the peripheral speed of the applicator roll to a value considerably less than the linear speed of the web it is possible to ensure that the applicator roll picks up from a suitable supply source only that amount of coating medium required to deposit a coating of the desired thickness on the web surface. An independent metering roll or doctor blade cooperating with the applicator roll is therefore not required.
  • the peripheral speed of the applicator roll is conveniently within a range of from 0.001 to 0.4 of the linear speed of the web, although a considerable speed differential is preferred such that ratio of the roll to web speeds is from 0.01:1 to 0.3:1, preferably from 0.015:1 to 0.15:1, and particularly preferably from 0.02:1 to 0.05:1.
  • a polyolefin web travelling at 1500 feet/minute (7.6 metres/sec) is conveniently coated by an applicator roll contra-rotating at a peripheral speed of 50 feet/minute (0.25 metres/sec), i.e. a roll to web speed ratio of about 0.033:1.
  • the peripheral speed of the applicator roll is within a range of from 1 to 500 feet/minute (0.005 to 2.5 metres/sec), and preferably is maintained between 10 and 150 feet/minute (0.05 to 0.76 metres/sec).
  • Rotation of the application roll at a suitable peripheral speed is effected by conventional driving means.
  • a pulley-mounted endless belt system coupled to a prime mower, such as an electrical motor provides a conveniently smooth, variable-speed drive means for the applicator roll without requiring a complex gearing system.
  • the coating system of the present invention operating as it does, in the absence of mechanical metering means cooperating with the applicator roll, depends, inter alia, on the establishment of an appropriate relationship between the peripheral speed of the applicator roll and the viscosity characteristics of the coating medium to ensure that the correct amount of coating medium is entrained on the roll surface at the area of contact with the web to ensure transfer to the web surface of a coating layer of the desired thickness.
  • the peripheral speed--of the applicator roll should therefore be controlled in accordance with the relationship: wherein the symbols represent the hereinbefore specified parameters.
  • the thickness of the web coating layer deposited on the web is, of course, reduced (compared to h - the equilibrium thickness of the entrained coating medium on the applicator roll surface) in proportion to the ratio of speeds of the roll and web.
  • Coating medium picked up from a suitable source or reservoir by the applicator roll is conveyed on the surface thereof to the junction at which the coated web disengages from the contra-rotating roll.
  • a distinct wedge or "bead" of coating medium supported by contact with both the web and roll.
  • a layer of coating medium the thickness of which depends on the equilibrium balance achieved between the volume of coating medium forwarded under the influence of surface tension and inertia forces interacting with the roll and the volume of coating medium flowing from the roll surface under gravity.
  • this layer it is the thickness of this layer, immediately before it merges into the "bead”, measured in a direction radially outwards from the rotational axis of the applicator roll which is herein referred to as the "equilibrium thickness" (h) of the entrained coating medium.
  • the thickness of layer h which should not exceed 5.0 mm and is preferably from 0.025 to 0.5 mm, is conveniently measured by conventional techniques - for example by means of a travelling microscope radially directed towards the applicator roll axis and focussed in turn on the roll surface and on the outermost surface of the coating layer entrained thereon.
  • a knowledge of the solids content and density of the coating medium and of the relative speeds of web and applicator roll enables the thickness of layer h to be derived from the measured thickness of the dry coating on the web surface by simple calculation - on the basis that all of the coating medium entrained on the roll surface is spread onto the web.
  • k in the aforementioned relationship is from 0.01 to 100 and is preferably from 0.1 to 50.
  • k is desirably maintained within a range- of from 0.25 to 25, preferably from 0.5 to 10, a preferred specific value of k being 3.7.
  • the dynamic viscosity of the coating medium may vary over a wide range - for example, from 1 centipoise (water thin) to the order of 50,000 centipoise, i.e. from about 0.001 to 50 Nsm- 2 , measured at ambient temperature, i.e. generally of the order of 20°C, but the low applicator to web speed ratio technique of this invention has proved particularly effective with coating media of relatively low viscosity - for example from 0.001 to 1.0 Nsm- 2 , and particularly from 0.001 to 0.1 Nsm- 2 , a preferred dynamic viscosity range being from 0.0015 to 0.06 Nsm- 2 at 20°C.
  • the web cooperates with the applicator roll over an arcuate segment of the roll surface such that the web is spread uniformly on the roll surface.
  • the arc contact angle being the angle at the rotational axis of the roll subtended by that arc of the roll surface engaged by the web, has a minimum value of 5°, and may be increased to any value at which an improvement in the quality of the deposited coating is discernible.
  • the maximum value of arc contact angle is determined by the geometry of the system and will seldom exceed 90°.
  • an arc contact angle of from 8 to 45° is employed.
  • the web is partially wrapped around a resilient-surfaced backing roll cooperating with the applicator roll to define a nip through which the web travels, the separation between the nip rolls being maintained equal to the combined thickness of the web and the coating deposited thereon. Consequently, there is a high risk of damage to the web, in the nip, resulting from the speed differential between the backing roll, which rotates at the same speed and in the same direction as the web, and the contra-rotating applicator roll.
  • the present invention enables reverse roll coating to be effected in the absence of a backing roll.
  • the path of the web be stabilised by engagement of the web with web stabilising means positioned downstream of the applicator roll.
  • the web stabilising means suitably comprises a relatively rigid member - for example, of aluminium with a suitably polished surface, extending across the width of the web and cooperating with the opposed surface of the web to that engaging the applicator roll, the member engaging the web downstream of the point at which the web ceases to contact the applicator roll and sufficiently close thereto to reduce vibration of the web to an acceptable magnitude in the vicinity of the applicator roll.
  • the stabilising member may be a stationary rod or bar, or, preferably, a roll rotatable in the direction of travel of the web. Desirably, the diameter of the stabilising roll should exceed that of the applicator roll, the diameter ratio of stabilising to applicator roll being preferably within a range of from 1.01:1 to 4:1.
  • the coated web formed by transfer of the coating medium from the applicator roll to the web may be subjected to conventional treatments.
  • smoothing of the applied coating layer may be effected by contacting the coated surface with a smoothing assembly comprising, for example, at least one polished rod or bar, or, preferably, a plurality of smoothing rolls at least some of which rotate in a direction contrary to the direction of travel of the web.
  • Typical smoothing rolls are of mild steel with a chromium plated and polished surface.
  • Coatings applied in accordance with the present invention may be dried, if necessary, by conventional methods, for example - by passing the coated web through an air oven maintained at an appropriate temperature.
  • a float oven in which the coated web floats on a current of heated air is particularly suitable.
  • the speed at which webs may be coated according to the invention depends on several factors including the material of the web and the thickness of the applied coatings. However, we have observed that polymeric films are suitably coated at relatively high linear speeds - for example of the order of 1,200 to 2,000 feet per minute (6 to 10 metres/second), i.e. at significantly higher speeds than attained by conventional reverse roll coating techniques.
  • the method of the invention is applicable to the coating of a single web surface or, if desired, to the sequential application of coating medium to each of the two opposed outermost surfaces of a web.
  • sequential coating stations may be followed by a single smoothing assembly, with smoothing members cooperating with each coated surface, and, if desired, by a single oven assembly for simultaneously drying both coated surfaces of the web.
  • a heat-sealable coating medium may be applied to a polymeric web the surface of which has already been treated with a primer medium - such as an interpolymerised condensation resin of the kind described in British patent 1 134 876 or in British patent 1 174 328.
  • Suitable flowable, polymeric, heat-sealable coating media include copolymers of vinylidene chloride with acrylonitrile because they yield hard coatings with good heat-seal strengths, and are also resistant to moisture and have low gas permeability. It is preferred to use. copolymers containing between 80% and 95% by weight of vinylidene chloride with from 5% to 20% by weight acrylonitrile. These copolymers may contain other monomers such as acrylic acid, itaconic acid and methacrylic acid, but a particularly preferred heat-sealable resin comprises a copolymer containing 88 weight % of vinylidene chloride and 12 weight % of acrylbnitrile.
  • the heat-seal coating medium may be applied to the web as a solution or a dispersion, but the solvent or dispersant should not be such that it will dissolve any resin coating already on the web surface.
  • a vinylidene chloride-acrylonitrile copolymer coating medium is conveniently employed as an aqueous dispersion containing from about 30 to about 60% by weight of the copolymer based on the weight of the dispersion, i.e. a dispersion having a dynamic viscosity range at 20°C from about 0.0015 to about 0.06 Nsm- 2,
  • Coating medium may be supplied to the surface of the, or each, applicator roll by conventional techniques - for example, by partial immersion of the rotating applicator roll in a bath containing a volume of the liquid coating medium, the roll preferably being immersed to the level of its rotational axis in the medium.
  • the thickness of the coating applied to the, or each, surface of the web can be adjusted, inter alia, by appropriate selection of the rotational speed of the applicator roll.
  • a heat-sealable resin, of the kind hereinbefore described, is suitably deposited on a polymeric web to form a coating having a wet thickness, i.e. prior to drying, of the order of from 1 to 100 Il m, but, to facilitate drying, the wet thickness of the coating is desirably maintained between 1 and 25 ⁇ m, preferably from 1.5 to 10 ⁇ m, and particularly preferably from 2 to 8 ⁇ m.
  • the wet thickness of the coating may be varied over a wide range depending on the solids content of the coating medium and the desired thickness of the subsequently dried coating.
  • the thickness of the coatings on opposed surfaces of the web may, but neet not, be identical.
  • the equilibrium thickness of the coating medium entrained on the applicator roll will be correspondingly greater than the wet coat thickness on the web - approximately in proportion to the ratio of the speed of the web to that of the applicator roll.
  • Coatings applied in accordance with the present invention may contain agents, such as anti-static agents, anti-oxidants, ultra-violet light stabilisers, and the like, to control or improve the characteristics of the coated web.
  • agents such as anti-static agents, anti-oxidants, ultra-violet light stabilisers, and the like, to control or improve the characteristics of the coated web.
  • Webs such as paper, paperboard, cellulosic films, metal foils, polymeric films, and laminates thereof, are suitably coated or printed by the techniques of the present invention.
  • Typical polymeric films include oriented, particularly biaxially oriented, films formed in conventional manner from polyesters such as polyethylene terephthalate and polyethylene-1,2-diphenoxy- ethane-4,4' dicarboxylate, and from polymers and copolymers of 1-olefins such as ethylene, propylene, butene-1, and 4-methylpentene-1.
  • thermoplastic polymer film is that formed from a high molecular weight stereoregular predominantly crystalline polymer of propylene, either in the form of a homopolymer or copolymerised with minor quantities (e.g. up to 15% by weight of the copolymer) of at least one other unsaturated monomer, such as ethylene.
  • Films treated according to the present invention may vary in thickness depending on the intended application, films having a thickness of from 2 to 150 microns being of general utility. Films intended for use in packaging operations are suitably wthin a thickness range of from 10 to 50 microns.
  • a heat sealable polyolefin film is prepared by forwarding an oriented polyolefin film in contact with the surface of an applicator roll, supplying a solution or dispersion of a heat sealable coating medium to the surface of the applicator roll, rotating the applicator roll in a direction contrary to the direction of forward movement of the film to coat the film, and drying the coated film, characterised by maintaining the film in contact with the applicator roll surface over an arc contact angle of from 5 to 90°, by supplying to the applicator roll surface a solution or dispersion of a heat sealable coating medium having a dynamic viscosity of from 0.001 to 0.1 Nsm-2 at 20°C, and by maintaining the peripheral velocity of the applicator roll within a range of from 0.001 to 0.4 of the forward speed of the film such that a layer of coating medium of equilibrium thickness not exceeding 5.0 mm is entrained on the surface of the
  • a polymeric film web 10 is fed at a selected linear speed from a supply source (not shown) around idler roll 11, into contact with an arcuate portion of the surface of applicator roll 12, and is removed therefrom around idler roll 13 so positioned that the zone of contact between the web and applicator roll surface subtends an arc contact angle a of the order of 10° at the rotational axis 14 of the applicator roll.
  • Applicator roll 12 rotates, as indicated by arrow A, in a direction contrary to the direction of movement of web 10, and at a peripheral speed less than the linear speed of the web.
  • a bath 15 contains a volume of liquid coating medium 16 maintained at a depth such that the applicator roll is immersed therein to the level of its rotational axis 14. Surplus coating liquid overflowing from the bath can, if desired, be collected and recycled to the bath by means of suitable pumping equipment (not shown).
  • Rotation of applicator roll 12 creates a dynamic meniscus 17 of coating liquid which progressively forms an equilibrium layer 18 of relatively constant thickness at the roll surface as a balance is achieved between the amount of liquid entrained on the roll by surface tension and liquid inertia and that flowing back into the bath by virtue of gravity and viscosity factors.
  • Contact between the web and applicator roll ensures virtually complete transfer of the coating medium from the surface of the roll to that of the web, the coating medium in equilibrium layer 18 being wiped into a wedge or bead 19 at the interface between the web and roll surface and thence into a uniform layer 20 on the web surface, the thickness of layer 20 being attenuated relative to that of equilibrium layer 18 in proportion of the speed differential between web 10 and roll 12.
  • Figure 2 illustrates a system similar to that of Figure 1 with the addition of web stabilising means in the form of a roll 21 of diameter exceeding that of applicator roll 12 and positioned relative thereto so that the initial point of contact 22 between the uncoated surface of web 10 and roll 21 is downstream, in the direction of travel of the web, of the point 23 at which the opposite surface of the web ceases to contact applicator roll 12.
  • the proximal positioning of roll 21 relative to applicator roll 12 reduces vibration of web 10 thereby improving the stability of the wedge 19 of coating medium and ensuring that the latter is transferred smoothly to web 10 to form a highly uniform coating layer 20 on the web surface.
  • Stabilising roll 21 may be independently driven at a suitable speed or may idle in contact with the web, and is suitably fabricated from a light metal such as aluminium.
  • a polyolefin web 50 is unwound from a supply roll 51 and fed around idler guide roll 52, through tension-controlling nip rolls 53, 54 and around idler roll 55 to a reverse roll coating assembly generally designated 56 comprising a feed roll 57, a relatively narrow diameter applicator roll 58, contra-rotating in a bath 59 of liquid coating medium 60, and a stabilising roll 61 of diameter exceeding that of applicator roll 58.
  • Stabilising roll 61 being in contact with the dry surface of web 50 is undriven, and allowed to co-rotate by frictional contact with the web.
  • the unilaterally coated web then traverses vacuum roll 62, which engages the uncoated web surface, and passes to a second reverse roll assembly, designated 63, for coating the second surface of the web, assembly 63 comprising a feed roll 64, an applicator roll 65, contra-rotating relative to the web in a bath 66 of liquid coating medium 67, and a stabilising roll 68 of greater diameter than that of applicator roll 65.
  • Stabilising roll 68 being in contact with the initially coated surface of web 50, and therefore achieving only slight frictional engagement therewith, is driven at a speed substantially equal to that of the web, and preferably in a direction contrary to the direction of movement of the web to smooth, and eliminate bubbles from, the initially deposited coating layer.
  • the web, now coated on each surface, is fed through a bank 69 of smoothing rollers 70, 71, rollers 70 contra-rotating in contact with one surface of the coated web, and rollers 71 contra-rotating in contact with the other coated surface.
  • the coated web traverses an air float drying oven 72 in which the web is suspended on currents of warm air to ensure that the smoothed coatings are dried before making contact with a solid roll surface.
  • the dried web After traversing idler guide roll 73, the dried web passes through the nip between guide roll 74 and the first of two internally-refrigerated cooling rolls 75, 76, the web being cooled by intimate contact with the surfaces thereof, and is then fed between tension-controlling nip rolls 77, 78 and onto wind-up roll 79.
  • one or more heated rolls may be interposed in the web path between guide roll 73 and cooling roll 75 to flatten the web, integrate the coating and effect tensioned thermal relaxation of the web in the manner disclosed in UK Patent j 457 940.
  • the web to be coated was a biaxially oriented, heat-seat and discharge treated polypropylene film 24 microns (pm) thick and 28 inches (711 mm) wide, having on each surface thereof a gravure coated anchor layer of about 0.5 gauge thickness (0.127 ⁇ m) of an interpolymerised resin containing 38.5 parts of styrene, 44 parts of ethyl acrylate, 2.5 parts of methacrylic acid, and 15 parts of acrylamide condensed with 5.2 parts of formaldehyde in n-butanol.
  • the second reverse roll assembly 63 was maintained in position and the film was fed therethrough, but coating medium was not supplied to bath 66, so that only the uppermost surface of the web passing through float oven 72 had a heat-sealable coating deposited thereon.
  • the anchor-coated polypropylene film web was fed through the system of Figure 3 in the direction shown at a forward speed of 1499 feet/minute (7.62 m/s) so as to contact the applicator roll 58 over an arc contact angle of about 10°, the applicator roll having a diameter of 2 inches (50.8 mm) and being immersed up to its rotational axis in the liquid coating medium in bath 59.
  • Undriven stabilising bar 61 of diameter 5 inches (127 mm) was positioned so that the surface thereof was radially spaced apart from the surface of applicator roll 58 by about 0.0625 inch (1.6 mm).
  • the peripheral speed of the applicator roll in a clockwise direction i.e. contrary to the direction of forward movement of the web, was adjusted to 47 feet/minute (0.239 m/s) so that substantially all of the coating medium picked up by the applicator roll was transferred to the web and smoothed thereon by' spreading rolls 70 rotating contrary to the direction of movement of the web at a peripheral speed of about 0.6 of the forward speed thereof.
  • the ratio of applicator roll to web speed was therefore 0.0314:1.
  • the coated web was dried in air-float oven 72 at a temperature of about 140°C, and the thickness of the dried coating on the web was found to be 7.25 gauge (1.84,um).
  • the heat-sealable coating was of uniform thickness across the width of the web and exhibited good adhesion to the anchor-coated substrate.
  • the optical properties of the coated film were excellent, the Gardner Haze value being 2.8 and the Gardner Gloss value being 103, comparable values for a similar film to which an identical coating had been applied by conventional techniques being 3.9 for Haze and 98 for Gloss.
  • Example 1 The procedure of Example 1 was repeated save that the solids content of the vinylidene chloride-acrylonitrile copolymer in the aqueous coating medium (and hence the viscosity thereof) and the relative speeds of the applicator roll and web were varied in accordance with the schedule of the accompanying Table.
  • contra-rotating roll 65 was 3 inches (76.2 mm), and that of the undriven stabilising roll 68 was 5 inches (127 mm), the surfaces of the two rolls being radially spaced apart by about 0.0625 inch (1.6 mm).
  • Example 2 the coating assembly was set up in the manner of Example 1, and the aqueous heat-sealable coating dispersion, containing 36 wt % of the vinylidene chloride-acrylonitrile copolymer, supplied to bath 59, bath 66 not being supplied with coating medium.
  • the anchor-coated polyp-opylene film web was fed through the coating assembly at a constant speed of 300 feet/minute (1.52 m/s), and the peripheral speed of applicator roll 58 in a clockwise direction progressively increased from zero. Perfect coating behaviour was observed as the applicator roll speed progressively increased to 90 feet/minute (0.46 m/s), i.e. a ratio of applicator roll to web speed of 0.303:1. As the applicator roll speed was further increased above about 101 feet/minute (0.51 m/s), i.e.

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Claims (12)

1. Procédé pour le revêtement d'une face ou surface d'une bande consistant à faire progresser la bande en contact avec la surface d'un rouleau applicateur, à amener un agent de revêtement fluide à la surface du rouleau applicateur et à faire tourner le rouleau applicateur dans une direction opposée à la direction de progression de la bande à une vitesse périphérique inférieure à la vitesse de progression de cette bande, caractérisé par l'absence de moyens coopérant avec la surface du rouleau applicateur pour doser l'agent de revêtement sur celui-ci, et par le fait que la viscosité dynamique de l'agent de revêtement et la vitesse périphérique du rouleau applicateur sont choisies chacune selon la formule:
Figure imgb0008
de façon telle qu'une couche d'agent de revêtement ayant une épaisseur d'équilibre ne dépassant pas 5,0 mm soit entraînée sur la surface du rouleau applicateur pour son transfert à la surface de la bande, et que le rapport entre la vitesse périphérique du rouleau applicateur et la vitesse de progression de la bande est maintenu à une valeur ne dépassant pas 0,4:1, formule dans laquelle:
h est l'épaisseur d'équilibre (mm) de l'agent de revêtement entraîné sur la surface du rouleau applicateur, mesurée radialement vers l'extérieur à partir de l'axe de rotation du rouleau applicateur en un point de la surface de ce rouleau applicateur situé immédiatement avant le point où l'agent de revêtement entraîné rejoint une zone cunéiforme formée à la jonction à laquelle la bande revêtue quitte le rouleau applicateur,
k a une valeur allant de 0,01 à 100,
r¡ est la viscosité dynamique (Nsm-2) de l'agent de revêtement à la température ambiante, et
U est la vitesse périphérique (ms-1) du rouleau applicateur.
2. Procédé suivant la revendication 1, caractérisé en ce que la rapport entre la vitesse périphérique du rouleau applicateur et la vitesse de progression de la bande est compris entre 0,015:1 et 0,15:1.
3. Procédé suivant la revendication 1 ou 2, caractérisé en ce que la viscosité dynamique de l'agent de revêtement est comprise entre 0,001 et 0,1 Nsm-2 à 20°C.
4. Procédé suivant l'une quelconque des revendications précédentes, caractérisé en ce que k est compris entre 0,25 et 25.
5. Procédé suivant l'une quelconque des revendications précédentes, caractérisé en ce que h est compris entre 0,025 et 0,5 mm.
6. Procédé suivant l'une quelconque des revendications précédentes, caractérisé en ce que l'épaisseur à l'état humide du revêtement déposé à la surface de la bande est comprise entre 1,0 et 25 microns.
7. Procédé suivant l'une quelconque des revendications précédentes, caractérisé en ce que la bande coopère avec la surface du rouleau applicateur sur un arc de contact correspondant à un angle compris entre 8 et 45°.
8. Procédé suivant l'une quelconque des revendications précédentes, caractérisé en ce que le trajet de la bande est stabilisé pour éviter une vibration en aval du rouleau applicateur.
9. Procédé suivant l'une quelconque des revendications précédentes, caractérisé en ce que l'agent de revêtement déposé à la surface de la bande est thermo-scellable.
10. Procédé suivant l'une quelconque des revendications précédentes, caractérisé en ce que la bande est un film polymère orienté.
11. Procédé de revêtement suivant la revendication 1 pour la production d'un film de polyoléfine thermo-scellable consistant à faire progresser un film de polyoléfine orienté en contact avec la surface d'un rouleau applicateur, à amener une solution ou une dispersion d'un agent de revêtement thermo-scellable à la surface du rouleau applicateur, à faire tourner le rouleau applicateur dans une direction opposée à la direction de progression du film pour revêtir le film, et à sécher le film revêtu, caractérisé en ce qu'on maintient le film en contact avec la surface du rouleau applicateur sur un arc de contact correspondant à un angle de 5 à 90°, on amène à la surface du rouleau applicateur une solution ou une dispersion d'un agent de revêtement thermo-scellable ayant une viscosité dynamique allant de 0,001 à 0,1 Nsm-2 à 20°C, et on maintient la vitesse périphérique du rouleau applicateur dans une fourchette représentant de 0,001 à 0,4 fois la vitesse de pregression du film, de telle sorte qu'une couche d'agent de revêtement ayant une épaisseur d'équilibre ne dépassant pas 5,0 mm soit entraînée à la surface du rouleau applicateur et par suite transférée à la surface du film.
12. Appareil pour l'application d'un agent de revêtement liquide sur une surface d'une bande en mouvement, comprenant un rouleau applicateur pouvant tourner dans une direction opposée à la direction de déplacement de la bande, un réservoir pour fournir l'agent de revêtement liquide à la surface du rouleau applicateur et des moyens pour fair progesser la bande en contact avec la surface du rouleau applicateur, caractérisé par des moyens de guidage pour maintenir la bande en contact avec la surface du rouleau applicateur sur un arc de contact correspondant à un angle de 5 à 90°, par l'absence de moyens coopérant avec la surface du rouleau applicateur pour doser l'agent de revêtement sur elle, et par des moyens pour faire tourner le rouleau applicateur en sens opposé à la direction de déplacement de la bande à une vitesse périphérique ne dépassant pas 0,4 fois la vitesse de progression de la bande, de telle sorte qu'en l'absence de ces moyens de dosage une couche uniforme d'agent de revêtement ayant une épaisseur d'équilibre ne dépassant pas 5,0 mm puisse être entraînée à partir du réservoir à la surface du rouleau applicateur pour son transfert à la surface de la bande.
EP78300013A 1977-06-23 1978-06-02 Procédé et dispositif pour enduire une bande Expired EP0000241B1 (fr)

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GB2630777 1977-06-23
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EP (1) EP0000241B1 (fr)
JP (1) JPS5441945A (fr)
AR (1) AR220912A1 (fr)
AU (1) AU3694878A (fr)
BR (1) BR7803890A (fr)
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PT68198A (en) 1978-07-01
JPS629381B2 (fr) 1987-02-27
ZA783213B (en) 1979-06-27
DE2861151D1 (en) 1981-12-24
AR220912A1 (es) 1980-12-15
DK269878A (da) 1978-12-24
ES471083A1 (es) 1979-12-16
AU3694878A (en) 1979-12-13
JPS5441945A (en) 1979-04-03
BR7803890A (pt) 1979-01-09
US4267215A (en) 1981-05-12
EP0000241A1 (fr) 1979-01-10
FI782003A (fi) 1978-12-24

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