WO2017198296A1 - Apparatus for continuous processing of a flexible substrate in a vacuum and method therefor - Google Patents

Apparatus for continuous processing of a flexible substrate in a vacuum and method therefor Download PDF

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Publication number
WO2017198296A1
WO2017198296A1 PCT/EP2016/061136 EP2016061136W WO2017198296A1 WO 2017198296 A1 WO2017198296 A1 WO 2017198296A1 EP 2016061136 W EP2016061136 W EP 2016061136W WO 2017198296 A1 WO2017198296 A1 WO 2017198296A1
Authority
WO
WIPO (PCT)
Prior art keywords
doctor blade
pressure
force
blade assembly
counter
Prior art date
Application number
PCT/EP2016/061136
Other languages
French (fr)
Inventor
Andreas Sauer
Gunther Gerber
Stefan Hein
Rainer Demuth
Original Assignee
Applied Materials, Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Applied Materials, Inc. filed Critical Applied Materials, Inc.
Priority to KR1020187036754A priority Critical patent/KR102224515B1/en
Priority to JP2018560603A priority patent/JP6751447B2/en
Priority to CN201680085819.XA priority patent/CN109153254B/en
Priority to PCT/EP2016/061136 priority patent/WO2017198296A1/en
Priority to TW106115931A priority patent/TWI695908B/en
Publication of WO2017198296A1 publication Critical patent/WO2017198296A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F31/00—Inking arrangements or devices
    • B41F31/02—Ducts, containers, supply or metering devices
    • B41F31/027—Ink rail devices for inking ink 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
    • B05C1/0813—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 means for supplying liquid or other fluent material to 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
    • B05C11/00—Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
    • B05C11/02—Apparatus for spreading or distributing liquids or other fluent materials already applied to a surface ; Controlling means therefor; Control of the thickness of a coating by spreading or distributing liquids or other fluent materials already applied to the coated surface
    • B05C11/04—Apparatus for spreading or distributing liquids or other fluent materials already applied to a surface ; Controlling means therefor; Control of the thickness of a coating by spreading or distributing liquids or other fluent materials already applied to the coated surface with blades
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F33/00—Indicating, counting, warning, control or safety devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B1/00—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means
    • B05B1/02—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means designed to produce a jet, spray, or other discharge of particular shape or nature, e.g. in single drops, or having an outlet of particular shape
    • B05B1/08—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means designed to produce a jet, spray, or other discharge of particular shape or nature, e.g. in single drops, or having an outlet of particular shape of pulsating nature, e.g. delivering liquid in successive separate quantities ; Fluidic oscillators
    • B05B1/083—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means designed to produce a jet, spray, or other discharge of particular shape or nature, e.g. in single drops, or having an outlet of particular shape of pulsating nature, e.g. delivering liquid in successive separate quantities ; Fluidic oscillators the pulsating mechanism comprising movable parts
    • 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
    • B05C1/0873—Controlling means responsive to conditions of the liquid or other fluent material, of the ambient medium, of the roller or of the work
    • B05C1/0878—Controlling means responsive to conditions of the liquid or other fluent material, of the ambient medium, of the roller or of the work responsive to the pressure applied between two rollers, e.g. between the coating roller and a backing roller or between the coating roller and a dosing roller

Definitions

  • the present disclosure relates to apparatuses for continuous processing of a substrate.
  • embodiments of the present disclosure relate to apparatuses for depositing material on a flexible substrate.
  • embodiments of the present disclosure relate to apparatuses for depositing a liquid material on a flexible substrate under vacuum conditions.
  • embodiments as described herein may particularly relate to apparatuses being equipped with a doctor blade chamber for use in a rotary coating or printing processes under vacuum conditions.
  • processing can include coating a flexible substrate with a desired material for a particular application.
  • materials used for coating flexible substrates can include polymers, dyes, metals, semiconductors or dielectric materials.
  • systems performing this task include a process drum for transporting the substrate through a processing region, e.g. in order to coat or print the substrate.
  • processing systems are typically referred to as rotary systems or Roll-to-roll (R2R) systems.
  • a coating or inking unit is provided which is equipped with a doctor blade which is pressed against an outer surface of a coating or inking roller for controlling a layer thickness of liquid coating or inking material applied to the surface of the coating or inking roller.
  • an apparatus for continuous processing of a flexible substrate in a vacuum includes: a processing roller; a doctor blade assembly having a doctor blade extending in an axial direction of the processing roller; and a force transmission assembly configured for moving the doctor blade assembly towards a surface of the processing roller.
  • the force transmission assembly includes a pressure unit for applying a force on the doctor blade assembly and a counter- pressure unit for applying a counter- force on the doctor blade assembly.
  • an apparatus for continuous processing of a flexible substrate in a vacuum includes: a processing roller; a doctor blade assembly having a doctor blade extending in an axial direction of the processing roller; and a first force transmission assembly configured for moving the doctor blade onto a surface of the processing roller.
  • the first force transmission assembly includes a first pneumatic pressure unit for applying a force on the doctor blade assembly and a first pneumatic counter-pressure unit for applying a counter-force on the doctor blade assembly.
  • the first force transmission assembly is arranged at a first axial end of the doctor blade assembly.
  • the first force transmission assembly includes a first load transmission element connected to the doctor blade assembly.
  • the first load transmission element is configured for transmitting a force from the first pneumatic pressure unit to the doctor blade assembly and for transmitting a counter-force from the first pneumatic counter-pressure unit to the doctor blade assembly.
  • the apparatus includes a second force transmission assembly configured for moving the doctor blade onto the surface of the processing roller.
  • the second force transmission assembly includes a second pneumatic pressure unit for applying a force on the doctor blade assembly and a second pneumatic counter-pressure unit for applying a counter-force on the doctor blade assembly.
  • the second force transmission assembly is arranged at a second axial end of the doctor blade assembly opposing the first axial end of the doctor blade assembly.
  • the second force transmission assembly includes a second load transmission element connected to the doctor blade assembly.
  • the second load transmission element is configured for transmitting a force from the second pneumatic pressure unit to the doctor blade assembly and for transmitting a counter-force from the second pneumatic counter- pressure unit to the doctor blade assembly.
  • a method for providing a contact pressure of a doctor blade onto a surface of a processing roller includes applying a force on a doctor blade assembly comprising the doctor blade by using a pressure unit and controlling the contact pressure by applying a counter-force on the doctor blade assembly by a counter- pressure unit.
  • the disclosure is also directed to an apparatus for carrying out the disclosed methods including apparatus parts for performing the methods.
  • the method may be performed by way of hardware components, a computer programmed by appropriate software, by any combination of the two or in any other manner.
  • the disclosure is also directed to operating methods of the described apparatus. It includes a method for carrying out every function of the apparatus.
  • FIG. 1 shows a schematic perspective view of an apparatus for continuous processing of a flexible substrate in a vacuum according to embodiments described herein;
  • FIG. 2 shows a schematic perspective view of a portion of a doctor blade assembly of an apparatus as shown in FIG. 1;
  • FIG. 3 shows a schematic front view of an apparatus according to embodiments described herein;
  • FIGS. 4 A and 4B show schematic top views of opposing portions of an apparatus according to embodiments described herein;
  • FIGS. 5 A and 5B show corresponding more detailed views of the portions of the apparatus shown in FIGS. 4A and 4B;
  • FIGS. 6 A to 6C show block diagrams illustrating embodiments of a method for providing a contact pressure of a doctor blade onto a surface of a processing roller according to embodiments described herein.
  • FIG. 1 shows a schematic perspective view of an apparatus 100 for continuous processing of a flexible substrate in a vacuum according to embodiments described herein.
  • the apparatus includes a processing roller 110 and a doctor blade assembly 120 having a doctor blade 121 extending in an axial direction of the processing roller 110.
  • the apparatus includes a force transmission assembly 130 which is configured for moving the doctor blade assembly 120 towards a surface 111 of the processing roller 110.
  • the force transmission assembly 130 includes a pressure unit for applying a force on the doctor blade assembly and a counter-pressure unit for applying a counter-force on the doctor blade assembly.
  • the force transmission assembly 130 indicated in FIG. 1 is shown in more detail in FIGS. 4A, 4B, 5A and 5B.
  • an apparatus for continuous processing of a flexible substrate having a force transmission assembly beneficially the contact pressure of a doctor blade with a surface of a processing roller can be controlled and adjusted very accurately.
  • a counter-pressure unit for controlling and/or adjusting a contact pressure of the doctor blade with the surface of the processing roller
  • an apparatus can be provided in which said contact pressure can be controlled to be substantially independent of the ambient pressure.
  • an apparatus can be provided in which the contact pressure of the doctor blade with the surface of the processing roller can be controlled to be constant when a change of the ambient pressure occurs.
  • the change of the ambient pressure can be a change from a first ambient pressure, e.g. an ambient pressure at which the apparatus is set up, to a second ambient pressure, e.g. an ambient pressure at which the apparatus is operated during processing.
  • a first ambient pressure may be an atmospheric pressure
  • the second ambient pressure may be a vacuum pressure.
  • the apparatus includes a vacuum processing chamber.
  • the processing roller, the doctor blade assembly, and the force transmission assembly as described herein may be arranged within the vacuum processing chamber of the apparatus.
  • a "flexible substrate” may be characterized in that the substrate is bendable.
  • the flexible substrate may be a foil.
  • embodiments of the apparatus as described herein can be utilized for processing any kind of flexible substrates, e.g. for manufacturing coatings or electronic devices on flexible substrates.
  • a substrate as described herein may include materials like PET, HC-PET, PE, PI, PU, TaC, one or more metals, paper, combinations thereof, and already coated substrates like Hard Coated PET (e.g. HC-PET, HC-TAC) and the like.
  • the processing roller 110 may be an anilox roller or screen roller. Additionally, the apparatus may include one or more further processing rollers, for instance a transfer roller 115 as exemplarily shown in FIG. 1. In particular, the processing roller 110 may be arranged parallel to the further processing rollers of the apparatus, e.g. parallel to the transfer roller 115. Between the processing roller 110 and the transfer roller 115, a flexible substrate may be transported during processing, e.g. coating or printing of the flexible substrate, by rotating the processing roller 110 and the transfer roller 115. Accordingly, the processing roller 110 and the transfer roller 115 can be connected to a frame structure 160 of the apparatus 100, such that the processing roller 110 and the transfer roller 115 are rotatable around their longitudinal axis.
  • processing roller is to be understood as a roller which is used during processing of a flexible substrate as described herein.
  • processing the flexible substrate may include coating or printing the flexible substrate using a liquid deposition material or a liquid inking material.
  • the "processing roller” as described herein may be a cylinder, for example a cylinder of metal, ceramic or plastic, having an outer surface including fine dimples, also referred to as cells. More particularly, the "processing roller” according to embodiments described herein may be an anilox roller or screen roller.
  • the doctor blade assembly 120 may be configured to have an elongated structure extending in a parallel direction to the processing roller 110 and/or transfer roller 115.
  • the term "doctor blade assembly” is to be understood as an assembly which includes at least one elongated doctor blade.
  • a "doctor blade assembly” as described herein may include a doctor blade chamber.
  • the doctor blade assembly 120 may include a doctor blade chamber 125.
  • the doctor blade chamber 125 may include a first doctor blade 121 A extending in the axial direction of the processing roller 110 and a second doctor blade 12 IB extending in the axial direction of the processing roller 110.
  • the doctor blade chamber 125 as described herein can include a reservoir 126 for receiving liquid material to be deposited.
  • the reservoir 126 may be defined by two spaced apart doctor blades, e.g. a first doctor blade 121A and a second doctor blade 12 IB, both of which extend in the axial direction of the corresponding processing roller.
  • end plates (not shown) may be provided at opposing both ends of the doctor blades to define, in corporation with the two spaced apart doctor blades, the reservoir for the liquid material to be deposited.
  • the apparatus may include a supply device for supplying the liquid coating material or liquid inking material to the reservoir in the doctor blade chamber.
  • a supply device for supplying the liquid coating material or liquid inking material to the reservoir in the doctor blade chamber.
  • the liquid coating material or liquid inking material can be applied to the surface of the processing roller, e.g. the surface of an anilox roller, from the reservoir while the surface of the processing roller passes through the reservoir defined by the two doctor blades and end plates.
  • the apparatus of the present disclosure provides for obtaining high quality coating or printing results.
  • a force transmission assembly which is configured for providing a contact pressure of the doctor blade with the surface of the processing roller which is independent of the ambient pressure, a constant layer thickness of liquid coating material or liquid inking material on the processing roller can be provided throughout the coating or inking process.
  • embodiments of the force transmission assembly are configured such that during evacuation of the processing chamber and initially set up, contact pressure of the doctor blade with a corresponding surface of the processing roller may be maintained. Accordingly, embodiments as described herein provide for accurately and uniformly controlling a layer thickness of liquid coating material or liquid inking material supplied along the axial length on the surface of the processing roller.
  • the doctor blade assembly 120 may include a holding arrangement 140 attached to the doctor blade chamber 125, as exemplary shown in FIG. 2 showing a more detailed schematic perspective view of a portion of an apparatus as shown in FIG. 1.
  • the doctor blade assembly 120 may be connected to a holding arrangement 140 configured for holding the doctor blade assembly 120.
  • the holding arrangement may include a supporting element 141, e.g. a beam element, extending in the axial direction of the processing roller 110.
  • the supporting element 141 can be connected to the frame structure 160 of the apparatus 100 via a connecting element.
  • the connecting element may be configured for providing a rotational movement of the doctor blade assembly.
  • the rotational movement of the doctor blade assembly may include a rotation around an axis which is parallel to the axis of the processing roller 110.
  • the doctor blade assembly can be configured to be pivotable for moving the doctor blade assembly 120 towards and away from a surface 111 of the processing roller 110.
  • Such a configuration may in particular be beneficial for maintenance, e.g. when doctor blades or other parts of the doctor blade assembly need to be replaced.
  • FIG. 3 a schematic front view of an apparatus according to embodiments described herein is shown.
  • the doctor blade assembly 120 may have an elongated configuration extending parallel to the rotational axis 112 of the processing roller 110.
  • the doctor blade assembly may have a length of at least 50% or more of the length of the processing roller 110. More particularly, the doctor blade assembly may have a length of at least 75% or more of the length of the processing roller 110.
  • a first force transmission assembly 130A and second force transmission assembly 130B may be provided, as exemplary shown in FIG. 3.
  • the first force transmission assembly 130A and the second force transmission assembly 130B may be arranged at opposing ends of the doctor blade assembly 120.
  • the first force transmission assembly 130A can be arranged at a first axial end 120A of the doctor blade assembly 120
  • the second force transmission assembly 130B can be arranged at a second axial end 120B opposing the first axial end 120 A of the doctor blade assembly 120.
  • providing a first force transmission assembly 130A and second force transmission assembly 130B as described herein may be in particular beneficial for accurately and uniformly controlling a layer thickness of liquid coating material or liquid inking material supplied along the axial length on the surface of the processing roller.
  • providing a first force transmission assembly 130A and second force transmission assembly 130B as described herein is beneficial for accurately controlling and adjusting a contact pressure of the first doctor blade and the second doctor blade of a doctor blade chamber with the surface processing roller.
  • the first force transmission assembly 130A and the second force transmission assembly 130B are configured for moving the doctor blade assembly 120 onto the surface 111 of the processing roller 110. Further, as described in more detail with reference to FIGS. 4A, 4B, 5 A and 5B, the first force transmission assembly 130A and the second force transmission assembly 130B may be configured for controlling and adjusting a contact pressure of a doctor blade with a corresponding surface of a processing roller.
  • FIGS. 4 A and 4B show schematic top views of opposing portions of an apparatus having a doctor blade assembly and a force transmission assembly according to embodiments described herein.
  • FIGS. 5A and 5B corresponding more detailed views of the portions of the apparatus illustrated in FIGS. 4A and 4B are shown.
  • the term "force transmission assembly” is to be understood as an assembly which is configured for transmitting a force applied to the doctor blade assembly onto an outer surface of a processing roller as described herein.
  • a “force transmission assembly” as described herein may be configured for providing a contact force between a doctor blade of the doctor blade assembly onto a surface of a corresponding processing roller.
  • a “force transmission assembly” according to embodiments described herein can be configured for providing and adjusting a contact pressure of a doctor blade chamber with a surface of an anilox roller or a screen roller.
  • the force transmission assembly 130 includes a pressure unit 131 for applying a force Fi on the doctor blade assembly 120 and a counter-pressure unit 132 for applying a counter- force F 2 on the doctor blade assembly 120.
  • the pressure unit 131 and the counter-pressure unit 132 may be configured to be a pneumatic unit.
  • the force transmission assembly 130 may include a load transmission element 133, as exemplarily shown in FIGS. 4A, 4B, 5A and 5B. It is to be understood that although the features of a force transmission assembly according to embodiments described herein are described with reference to FIG. 5A showing a first force transmission assembly 130A as described herein, the description of the features of the first force transmission assembly may also apply to the features of the second force transmission assembly 130B, as exemplarily shown in FIGS. 3, 4B and 5B.
  • the term "load transmission element” is to be understood as an element which is configured for transmitting a load or a force generated by the pressure unit as described herein to the doctor blade assembly as described herein. Additionally, a “load transmission element” can be configured for transmitting a counter-load or a counter-force generated by the counter-pressure unit to the doctor blade assembly as described herein. [0031] Accordingly, according to embodiments which can be combined with any other embodiments described herein, the load transmission element 133 is configured for transmitting a force from the pressure unit 131 to the doctor blade assembly 120. Further, the load transmission element 133 may be configured for transmitting a counter- force from the counter-pressure unit 132 to the doctor blade assembly 120.
  • the load transmission element 133 can be configured for receiving a force Fi from the pressure unit 131 on a first surface 134 of the load transmission element 133 and for receiving a counterforce F 2 from the counter-pressure unit 132 on a second surface 135 of the load transmission element 133.
  • the second surface 5 135 of the load transmission element 133 may be located at an opposing side of the first surface 134 of the load transmission element 133.
  • the load transmission element 133 may have an S-shape, e.g. as shown in FIG. 5A, or a Z-shape, e.g. as shown in FIG. 5B.0
  • the load transmission element may be a plate extending in an axial direction of the processing roller.
  • a pressure unit is to be understood as a unit in which a pressure of a fluid is employed for generating a force or a5 movement.
  • a "pressure unit” as described herein may be a pneumatic unit in which a compressible fluid, particularly gas (e.g. air), is used for generating a force or a movement.
  • a pneumatic unit may in particular be beneficial for vacuum processing, because a pneumatic unit automatically reacts to the pressure change during evacuation of the processing chamber.
  • a "pressure0 unit” as described herein may be a hydraulic unit in which an incompressible fluid, particularly a liquid (e.g. oil or water), is used for generating a force or a movement.
  • counter-pressure unit is to be understood as a unit in which a pressure of a fluid is employed for5 generating a counter-force or a counter-movement to the force or the movement generated by the "pressure unit” as described herein.
  • a “counter- pressure unit” may be a pneumatic unit or a hydraulic unit similar to the "pressure unit” as described herein.
  • the apparatus may include a first pressure valve 151 configured for controlling a first pressure generated by the pressure unit 131. Additionally, a second pressure valve 152 configured for controlling a second pressure generated by the counter-pressure unit 132 may be provided.
  • the first pressure valve 151 and/or the second pressure valve 152 may be connected to a controller 150 which can be configured for controlling the first pressure and/or the second pressure. Accordingly, beneficially the contact pressure between doctor blades of the doctor blade assembly with the processing roller can precisely be controlled and adapted during operation of the apparatus as described herein, such that high-quality coating and printing results can be achieved.
  • the first pressure provided by the pressure unit 131 may be selected from a range having a lower limit of 2 bar, particularly a lower limit of 3 bar, more particularly a lower limit of 4 bar and having an upper limit of 4 bar, particularly an upper limit of 6 bar, more particularly an upper limit of 8 bar.
  • the second pressure provided by the counter- pressure unit 132 may be selected from a range having a lower limit of 0 bar, particularly a lower limit of 1 bar, more particularly a lower limit of 2 bar and having an upper limit of 2 bar, particularly an upper limit of 4 bar, more particularly an upper limit of 6 bar.
  • the controller 150 of the apparatus may be configured for controlling a pressure difference between the pressure unit 131 and the counter-pressure unit 132.
  • the controller 150 may be configured for controlling the pressure difference to be constant.
  • the pressure difference may be selected from a range having a lower limit of 1 bar, particularly a lower limit of 1.5 bar and an upper limit of 3 bar, particularly 4 bar.
  • the pressure difference between the pressure unit 131 and the counter-pressure unit 132 may be 2 bar ⁇ 0.5 bar, particularly 2 bar ⁇ 0.1 bar, more particularly 2 bar ⁇ 0.05 bar.
  • the contact pressure between doctor blades of the doctor blade assembly with the processing roller can be controlled to be constant throughout a coating or printing process, such that the contact pressure may substantially be not influenced by any changes of the ambient pressure in the processing chamber, particularly during evacuation in which the ambient pressure changes from an atmospheric pressure to a vacuum pressure.
  • beneficially and initially set up contact pressure under atmospheric pressure conditions corresponds to the actual contact pressure during operation of the apparatus under vacuum conditions.
  • beneficially, by increasing the first pressure provided by the pressure unit as well as increasing the second pressure provided by the counter pressure unit the overall stability of the contact pressure between doctor blades of the doctor blade assembly with the processing roller can increased.
  • the apparatus may further include a monitoring device for monitoring the first pressure provided by the pressure unit 131 and/or for monitoring the second pressure provided by the counter-pressure unit 132.
  • the monitoring device may be a pressure sensor.
  • a first pressure sensor may be provided which is configured and arranged for measuring the first pressure provided by the pressure unit 131 and/or a second pressure sensor may be provided which is configured and arranged for measuring the second pressure provided by the counter-pressure unit 132.
  • the first pressure sensor and/or the second pressure sensor may be connected to the controller as described herein. Accordingly, beneficially the controller may be configured to adjust the first pressure and/or the second pressure, e.g. in the case that a measured pressure deviates from a preselected first pressure and/or second pressure as specified herein.
  • embodiments as described herein provide for automatic adaption or readjustment of the contact pressure from the doctor blades of the doctor blade assembly with the processing roller which may in particular be beneficial to compensate for abrasive wear effects of the doctor blades. Further, embodiments as described herein provide for adjusting the contact pressure of the doctor blades with the corresponding processing roller during operation of the apparatus which may be beneficial in the case that different processing conditions, particularly a different layer thickness of liquid coating or printing material, is to be selected during operation of the apparatus. Accordingly, embodiments as described herein provide for adapting and readjusting the contact pressure of doctor blades with a processing roller under vacuum conditions. In particular, the contact pressure may be controlled and adjusted without breaking an established vacuum during processing. Further, it is to be understood that embodiments described herein, particularly when the force transmission assembly includes pneumatic units, are configured to compensate for deformations of the processing roller, e.g. caused by thermal expansion.
  • the force transmission assembly 130 may include a guiding element 144 for guiding a movement of the doctor blade assembly 120 towards the surface 111 of the processing roller 110, as exemplarily shown in FIGS. 4A, 4B, 5 A and 5B.
  • the guiding element 144 may be a linear guiding element having low friction.
  • the guiding movement may be a movement which is substantially perpendicular to the axis of the processing roller. Accordingly, beneficially the doctor blades of the doctor blade assembly as described herein can be precisely positioned onto the surface of the corresponding processing roller.
  • a guiding element as described herein may also be beneficial for precisely adjusting the contact pressure of the doctor blades with the corresponding surface of the processing roller.
  • the doctor blade assembly particularly the doctor blade chamber, can be guided by the guiding element for providing a precise and guided movement of the doctor blade assembly towards the surface of the processing roller in order to provide the contact pressure.
  • FIGS. 6 A to 6C show block diagrams illustrating embodiments of a method 200 for providing a contact pressure of a doctor blade onto a surface of a processing roller.
  • the method includes applying 210 a force on a doctor blade assembly including the doctor blade by using a pressure unit and controlling 220 the contact pressure by applying a counter-force on the doctor blade assembly by using a counter-pressure unit, as exemplary illustrated by the block diagram shown in FIG. 6A.
  • applying 210 a force on a doctor blade assembly may include using a pressure unit according to embodiments described herein.
  • controlling 220 the contact pressure by applying a counter-force on the doctor blade assembly may include using a counter-pressure unit according to embodiments described herein. Accordingly, embodiments of the method as described herein beneficially provide for controlling and adjusting the contact pressure of a doctor blade with a surface of a processing roller very accurately. In particular, embodiments of the method as described herein provide for controlling said contact pressure substantially independent of the ambient pressure. Accordingly, with embodiments of the method as described herein, the contact pressure of the doctor blade with the surface of the processing roller can be controlled to be constant even if an ambient pressure change occurs.
  • controlling 220 the contact pressure includes generating 221 a pressure difference between a first pressure applied by the pressure unit on a load transmission element and a second pressure applied by the counter-pressure unit on the load transmission element.
  • generating 221 the pressure difference can include applying a force Fi from the pressure unit 131 on the first surface 134 of the load transmission element 133 and applying a counterforce F 2 from the counter-pressure unit 132 on the second surface 135 of the load transmission element 133.
  • generating 221 the pressure difference may include selecting the first pressure provided by the pressure from a range having a lower limit of 2 bar, particularly a lower limit of 3 bar, more particularly a lower limit of 4 bar and having an upper limit of 4 bar, particularly an upper limit of 6 bar, more particularly an upper limit of 8 bar. Further, generating 221 the pressure difference may include selecting the second pressure provided by the counter-pressure unit 132 from a range having a lower limit of 0 bar, particularly a lower limit of 1 bar, more particularly a lower limit of 2 bar and having an upper limit of 2 bar, particularly an upper limit of 4 bar, more particularly an upper limit of 6 bar.
  • controlling 220 the contact pressure may include using a first pressure valve 151 and/or a second pressure valve 152 as described herein.
  • controlling 220 the contact pressure may include using a controller 150 as described herein. Accordingly, embodiments of the method as described herein provide for automatic adaption or readjustment of the contact pressure from the doctor blades of the doctor blade assembly as described herein with a corresponding processing roller which may in particular be beneficial to compensate for abrasive wear effects of the doctor blades.
  • the method may include monitoring 230 the pressure difference, as exemplarily illustrated by the block diagram shown in FIG. 6B.
  • monitoring 230 the pressure difference may include using a monitoring device, e.g. a first pressure sensor and/or the second pressure sensor, as described herein.
  • a monitoring device e.g. a first pressure sensor and/or the second pressure sensor, as described herein.
  • embodiments of the method as described herein are configured for monitoring and adjusting a first pressure and/or a second pressure as specified herein, which may in particular be beneficial in the case that a measured pressure deviates from a preselected first pressure and/or second pressure as specified herein.
  • the method may further include controlling 240 the pressure difference to be constant such that the contact pressure of the doctor blade with the processing roller is independent of an ambient pressure.
  • controlling 240 the pressure difference to be constant may include selecting the pressure difference from a range having a lower limit of 1 bar, particularly a lower limit of 1.5 bar and an upper limit of 3 bar, particularly 4 bar.
  • controlling 240 the pressure difference between the pressure unit 131 and the counter-pressure unit 132 to be constant may include selecting the pressure difference to be 2 bar ⁇ 0.2 bar, particularly 2 bar ⁇ 0.1 bar, more particularly 2 bar ⁇ 0.05 bar.
  • embodiments of the apparatus as well as of the method as described herein are particularly suited for precisely adjusting and controlling a constant contact pressure of doctor blades of a doctor blade chamber with an anilox or screen roller, particularly for coating or printing of flexible substrates with a large substrate width.

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  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

An apparatus (100) for continuous processing of a flexible substrate in a vacuum is provided. The apparatus includes a processing roller (110); a doctor blade assembly (120) having a doctor blade (121) extending in an axial direction of the processing roller (110); and a force transmission assembly (130) configured for moving the doctor blade assembly (120) towards a surface (111) of the processing roller (110). The force transmission assembly (130) includes a pressure unit (131) for applying a force on the doctor blade assembly (120) and a counter-pressure unit (132) for applying a counter-force on the doctor blade assembly (120).

Description

APPARATUS FOR CONTINUOUS PROCESSING OF A FLEXIBLE SUBSTRATE IN A VACUUM AND METHOD THEREFOR
TECHNICAL FIELD
[0001] The present disclosure relates to apparatuses for continuous processing of a substrate. In particular, embodiments of the present disclosure relate to apparatuses for depositing material on a flexible substrate. More particularly, embodiments of the present disclosure relate to apparatuses for depositing a liquid material on a flexible substrate under vacuum conditions. For example, embodiments as described herein may particularly relate to apparatuses being equipped with a doctor blade chamber for use in a rotary coating or printing processes under vacuum conditions.
BACKGROUND
[0002] Processing of flexible substrates, such as plastic films, foils or paper, is in high demand in the packaging industry, semiconductor industries and other industries. For example, processing can include coating a flexible substrate with a desired material for a particular application. For instance, materials used for coating flexible substrates can include polymers, dyes, metals, semiconductors or dielectric materials. Typically, systems performing this task include a process drum for transporting the substrate through a processing region, e.g. in order to coat or print the substrate. Such processing systems are typically referred to as rotary systems or Roll-to-roll (R2R) systems.
[0003] Particularly, in coating or printing systems using a liquid coating or printing material, the liquid material supplied to a surface of the coating or inking roller needs to be accurately and uniformly controlled for obtaining good quality coating or printing results. Accordingly, in the field of rotary coating or printing machines, typically a coating or inking unit is provided which is equipped with a doctor blade which is pressed against an outer surface of a coating or inking roller for controlling a layer thickness of liquid coating or inking material applied to the surface of the coating or inking roller. While other factors such as viscosity of the liquid material, roller rotational speed and the like also affect the layer thickness of liquid material, the force with which the doctor blade is pressed against the surface of the coating or inking roller is more determinative for the thickness of the liquid material layer which is applied to the coating or inking roller.
[0004] However, accurately adjusting and controlling a constant contact pressure of the doctor blades with the coating or inking roller remains challenging, particularly for coating or printing of substrates with a large substrate width. SUMMARY
[0005] In view of the above, an apparatus for continuous processing of a flexible substrate in a vacuum and a method for providing a contact pressure of a doctor blade onto a surface of a processing roller according to the independent claims are provided. Further advantages, features, aspects and details are apparent from the dependent claims, the description and drawings.
[0006] According to one aspect of the present disclosure, an apparatus for continuous processing of a flexible substrate in a vacuum is provided. The apparatus includes: a processing roller; a doctor blade assembly having a doctor blade extending in an axial direction of the processing roller; and a force transmission assembly configured for moving the doctor blade assembly towards a surface of the processing roller. The force transmission assembly includes a pressure unit for applying a force on the doctor blade assembly and a counter- pressure unit for applying a counter- force on the doctor blade assembly.
[0007] According to another aspect of the present disclosure, an apparatus for continuous processing of a flexible substrate in a vacuum is provided. The apparatus includes: a processing roller; a doctor blade assembly having a doctor blade extending in an axial direction of the processing roller; and a first force transmission assembly configured for moving the doctor blade onto a surface of the processing roller. The first force transmission assembly includes a first pneumatic pressure unit for applying a force on the doctor blade assembly and a first pneumatic counter-pressure unit for applying a counter-force on the doctor blade assembly. The first force transmission assembly is arranged at a first axial end of the doctor blade assembly. The first force transmission assembly includes a first load transmission element connected to the doctor blade assembly. The first load transmission element is configured for transmitting a force from the first pneumatic pressure unit to the doctor blade assembly and for transmitting a counter-force from the first pneumatic counter-pressure unit to the doctor blade assembly. Further, the apparatus includes a second force transmission assembly configured for moving the doctor blade onto the surface of the processing roller. The second force transmission assembly includes a second pneumatic pressure unit for applying a force on the doctor blade assembly and a second pneumatic counter-pressure unit for applying a counter-force on the doctor blade assembly. The second force transmission assembly is arranged at a second axial end of the doctor blade assembly opposing the first axial end of the doctor blade assembly. The second force transmission assembly includes a second load transmission element connected to the doctor blade assembly. The second load transmission element is configured for transmitting a force from the second pneumatic pressure unit to the doctor blade assembly and for transmitting a counter-force from the second pneumatic counter- pressure unit to the doctor blade assembly.
[0008] According to a further aspect of the present disclosure, a method for providing a contact pressure of a doctor blade onto a surface of a processing roller is provided. The method includes applying a force on a doctor blade assembly comprising the doctor blade by using a pressure unit and controlling the contact pressure by applying a counter-force on the doctor blade assembly by a counter- pressure unit.
[0009] The disclosure is also directed to an apparatus for carrying out the disclosed methods including apparatus parts for performing the methods. The method may be performed by way of hardware components, a computer programmed by appropriate software, by any combination of the two or in any other manner. Furthermore, the disclosure is also directed to operating methods of the described apparatus. It includes a method for carrying out every function of the apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS [0010] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments. The accompanying drawings relate to embodiments of the disclosure and are described in the following: FIG. 1 shows a schematic perspective view of an apparatus for continuous processing of a flexible substrate in a vacuum according to embodiments described herein;
FIG. 2 shows a schematic perspective view of a portion of a doctor blade assembly of an apparatus as shown in FIG. 1; FIG. 3 shows a schematic front view of an apparatus according to embodiments described herein;
FIGS. 4 A and 4B show schematic top views of opposing portions of an apparatus according to embodiments described herein;
FIGS. 5 A and 5B show corresponding more detailed views of the portions of the apparatus shown in FIGS. 4A and 4B; and
FIGS. 6 A to 6C show block diagrams illustrating embodiments of a method for providing a contact pressure of a doctor blade onto a surface of a processing roller according to embodiments described herein.
DETAILED DESCRIPTION OF EMBODIMENTS [0011] Reference will now be made in detail to the various embodiments of the disclosure, one or more examples of which are illustrated in the figures. Within the following description of the drawings, the same reference numbers refer to same components. In the following, only the differences with respect to individual embodiments are described. Each example is provided by way of explanation of the disclosure and is not meant as a limitation of the disclosure. Further, features illustrated or described as part of one embodiment can be used on or in conjunction with other embodiments to yield yet a further embodiment. It is intended that the description includes such modifications and variations.
[0012] FIG. 1 shows a schematic perspective view of an apparatus 100 for continuous processing of a flexible substrate in a vacuum according to embodiments described herein. In particular, according to embodiments which can be combined with any other embodiments described herein, the apparatus includes a processing roller 110 and a doctor blade assembly 120 having a doctor blade 121 extending in an axial direction of the processing roller 110. Further, the apparatus includes a force transmission assembly 130 which is configured for moving the doctor blade assembly 120 towards a surface 111 of the processing roller 110. In particular, the force transmission assembly 130 includes a pressure unit for applying a force on the doctor blade assembly and a counter-pressure unit for applying a counter-force on the doctor blade assembly. The force transmission assembly 130 indicated in FIG. 1 is shown in more detail in FIGS. 4A, 4B, 5A and 5B.
[0013] Accordingly, by providing an apparatus for continuous processing of a flexible substrate having a force transmission assembly as described herein, beneficially the contact pressure of a doctor blade with a surface of a processing roller can be controlled and adjusted very accurately. In particular, by employing a counter-pressure unit for controlling and/or adjusting a contact pressure of the doctor blade with the surface of the processing roller, an apparatus can be provided in which said contact pressure can be controlled to be substantially independent of the ambient pressure. Accordingly, beneficially an apparatus can be provided in which the contact pressure of the doctor blade with the surface of the processing roller can be controlled to be constant when a change of the ambient pressure occurs.
[0014] For example, the change of the ambient pressure can be a change from a first ambient pressure, e.g. an ambient pressure at which the apparatus is set up, to a second ambient pressure, e.g. an ambient pressure at which the apparatus is operated during processing. In particular, the first ambient pressure may be an atmospheric pressure and the second ambient pressure may be a vacuum pressure. Accordingly, it is to be understood that embodiments as described herein provide for maintaining a constant contact pressure of a doctor blade with a corresponding processing roller during evacuation of a processing chamber in which the flexible substrate is processed.
[0015] Accordingly, although not explicitly shown in the figures, it is to be understood that according to embodiments which can be combined with any other embodiments described herein, the apparatus includes a vacuum processing chamber. In particular, the processing roller, the doctor blade assembly, and the force transmission assembly as described herein may be arranged within the vacuum processing chamber of the apparatus.
[0016] In the present disclosure, a "flexible substrate" may be characterized in that the substrate is bendable. For example, the flexible substrate may be a foil. In particular, it is to be understood that embodiments of the apparatus as described herein can be utilized for processing any kind of flexible substrates, e.g. for manufacturing coatings or electronic devices on flexible substrates. For example, a substrate as described herein may include materials like PET, HC-PET, PE, PI, PU, TaC, one or more metals, paper, combinations thereof, and already coated substrates like Hard Coated PET (e.g. HC-PET, HC-TAC) and the like.
[0017] With exemplary reference to FIG. 1, according to embodiments which can be combined with any other embodiments described herein, the processing roller 110 may be an anilox roller or screen roller. Additionally, the apparatus may include one or more further processing rollers, for instance a transfer roller 115 as exemplarily shown in FIG. 1. In particular, the processing roller 110 may be arranged parallel to the further processing rollers of the apparatus, e.g. parallel to the transfer roller 115. Between the processing roller 110 and the transfer roller 115, a flexible substrate may be transported during processing, e.g. coating or printing of the flexible substrate, by rotating the processing roller 110 and the transfer roller 115. Accordingly, the processing roller 110 and the transfer roller 115 can be connected to a frame structure 160 of the apparatus 100, such that the processing roller 110 and the transfer roller 115 are rotatable around their longitudinal axis.
[0018] In the present disclosure, the term "processing roller" is to be understood as a roller which is used during processing of a flexible substrate as described herein. In particular, processing the flexible substrate may include coating or printing the flexible substrate using a liquid deposition material or a liquid inking material. In particular, the "processing roller" as described herein may be a cylinder, for example a cylinder of metal, ceramic or plastic, having an outer surface including fine dimples, also referred to as cells. More particularly, the "processing roller" according to embodiments described herein may be an anilox roller or screen roller.
[0019] As exemplarily shown in FIG. 1, according to embodiments which can be combined with any other embodiments described herein, the doctor blade assembly 120 may be configured to have an elongated structure extending in a parallel direction to the processing roller 110 and/or transfer roller 115. In the present disclosure, the term "doctor blade assembly" is to be understood as an assembly which includes at least one elongated doctor blade. In particular, a "doctor blade assembly" as described herein may include a doctor blade chamber. [0020] With exemplary reference to FIGS. 1 and 2, according to embodiments which can be combined with any other embodiment described herein, the doctor blade assembly 120 may include a doctor blade chamber 125. In particular, the doctor blade chamber 125 may include a first doctor blade 121 A extending in the axial direction of the processing roller 110 and a second doctor blade 12 IB extending in the axial direction of the processing roller 110. For example, the doctor blade chamber 125 as described herein can include a reservoir 126 for receiving liquid material to be deposited. Particularly, the reservoir 126 may be defined by two spaced apart doctor blades, e.g. a first doctor blade 121A and a second doctor blade 12 IB, both of which extend in the axial direction of the corresponding processing roller. Further, end plates (not shown) may be provided at opposing both ends of the doctor blades to define, in corporation with the two spaced apart doctor blades, the reservoir for the liquid material to be deposited.
[0021] According to embodiments which can be combined with any other embodiments described herein, the apparatus may include a supply device for supplying the liquid coating material or liquid inking material to the reservoir in the doctor blade chamber. Accordingly, it is to be understood that the liquid coating material or liquid inking material can be applied to the surface of the processing roller, e.g. the surface of an anilox roller, from the reservoir while the surface of the processing roller passes through the reservoir defined by the two doctor blades and end plates.
[0022] In view of the embodiments as described herein, the skilled person understands that the apparatus of the present disclosure provides for obtaining high quality coating or printing results. In particular, by providing a force transmission assembly which is configured for providing a contact pressure of the doctor blade with the surface of the processing roller which is independent of the ambient pressure, a constant layer thickness of liquid coating material or liquid inking material on the processing roller can be provided throughout the coating or inking process. Further, embodiments of the force transmission assembly are configured such that during evacuation of the processing chamber and initially set up, contact pressure of the doctor blade with a corresponding surface of the processing roller may be maintained. Accordingly, embodiments as described herein provide for accurately and uniformly controlling a layer thickness of liquid coating material or liquid inking material supplied along the axial length on the surface of the processing roller. [0023] According to embodiments which can be combined with any other embodiments described herein, the doctor blade assembly 120 may include a holding arrangement 140 attached to the doctor blade chamber 125, as exemplary shown in FIG. 2 showing a more detailed schematic perspective view of a portion of an apparatus as shown in FIG. 1. In particular, the doctor blade assembly 120 may be connected to a holding arrangement 140 configured for holding the doctor blade assembly 120. The holding arrangement may include a supporting element 141, e.g. a beam element, extending in the axial direction of the processing roller 110. The supporting element 141 can be connected to the frame structure 160 of the apparatus 100 via a connecting element. For instance, the connecting element may be configured for providing a rotational movement of the doctor blade assembly. In particular, the rotational movement of the doctor blade assembly may include a rotation around an axis which is parallel to the axis of the processing roller 110. Accordingly, beneficially the doctor blade assembly can be configured to be pivotable for moving the doctor blade assembly 120 towards and away from a surface 111 of the processing roller 110. Such a configuration may in particular be beneficial for maintenance, e.g. when doctor blades or other parts of the doctor blade assembly need to be replaced.
[0024] In FIG. 3, a schematic front view of an apparatus according to embodiments described herein is shown. As shown in FIG. 3, the doctor blade assembly 120 may have an elongated configuration extending parallel to the rotational axis 112 of the processing roller 110. In particular, the doctor blade assembly may have a length of at least 50% or more of the length of the processing roller 110. More particularly, the doctor blade assembly may have a length of at least 75% or more of the length of the processing roller 110.
[0025] According to embodiments which can be combined with any other embodiments described herein, a first force transmission assembly 130A and second force transmission assembly 130B may be provided, as exemplary shown in FIG. 3. In particular, the first force transmission assembly 130A and the second force transmission assembly 130B may be arranged at opposing ends of the doctor blade assembly 120. For instance, the first force transmission assembly 130A can be arranged at a first axial end 120A of the doctor blade assembly 120, and the second force transmission assembly 130B can be arranged at a second axial end 120B opposing the first axial end 120 A of the doctor blade assembly 120. Accordingly, providing a first force transmission assembly 130A and second force transmission assembly 130B as described herein may be in particular beneficial for accurately and uniformly controlling a layer thickness of liquid coating material or liquid inking material supplied along the axial length on the surface of the processing roller. In particular, providing a first force transmission assembly 130A and second force transmission assembly 130B as described herein is beneficial for accurately controlling and adjusting a contact pressure of the first doctor blade and the second doctor blade of a doctor blade chamber with the surface processing roller.
[0026] Accordingly, it is to be understood that the first force transmission assembly 130A and the second force transmission assembly 130B are configured for moving the doctor blade assembly 120 onto the surface 111 of the processing roller 110. Further, as described in more detail with reference to FIGS. 4A, 4B, 5 A and 5B, the first force transmission assembly 130A and the second force transmission assembly 130B may be configured for controlling and adjusting a contact pressure of a doctor blade with a corresponding surface of a processing roller.
[0027] FIGS. 4 A and 4B show schematic top views of opposing portions of an apparatus having a doctor blade assembly and a force transmission assembly according to embodiments described herein. In FIGS. 5A and 5B, corresponding more detailed views of the portions of the apparatus illustrated in FIGS. 4A and 4B are shown.
[0028] In the present disclosure, the term "force transmission assembly" is to be understood as an assembly which is configured for transmitting a force applied to the doctor blade assembly onto an outer surface of a processing roller as described herein. In particular, a "force transmission assembly" as described herein may be configured for providing a contact force between a doctor blade of the doctor blade assembly onto a surface of a corresponding processing roller. More particularly, a "force transmission assembly" according to embodiments described herein can be configured for providing and adjusting a contact pressure of a doctor blade chamber with a surface of an anilox roller or a screen roller. [0029] With exemplary reference to FIG. 5A, according to embodiments which can be combined with any other embodiments described herein, the force transmission assembly 130 includes a pressure unit 131 for applying a force Fi on the doctor blade assembly 120 and a counter-pressure unit 132 for applying a counter- force F2 on the doctor blade assembly 120. In particular, the pressure unit 131 and the counter-pressure unit 132 may be configured to be a pneumatic unit. Further, the force transmission assembly 130 may include a load transmission element 133, as exemplarily shown in FIGS. 4A, 4B, 5A and 5B. It is to be understood that although the features of a force transmission assembly according to embodiments described herein are described with reference to FIG. 5A showing a first force transmission assembly 130A as described herein, the description of the features of the first force transmission assembly may also apply to the features of the second force transmission assembly 130B, as exemplarily shown in FIGS. 3, 4B and 5B.
[0030] In the present disclosure, the term "load transmission element" is to be understood as an element which is configured for transmitting a load or a force generated by the pressure unit as described herein to the doctor blade assembly as described herein. Additionally, a "load transmission element" can be configured for transmitting a counter-load or a counter-force generated by the counter-pressure unit to the doctor blade assembly as described herein. [0031] Accordingly, according to embodiments which can be combined with any other embodiments described herein, the load transmission element 133 is configured for transmitting a force from the pressure unit 131 to the doctor blade assembly 120. Further, the load transmission element 133 may be configured for transmitting a counter- force from the counter-pressure unit 132 to the doctor blade assembly 120. For example, as exemplarily shown in FIG. 5A or 5B, the load transmission element 133 can be configured for receiving a force Fi from the pressure unit 131 on a first surface 134 of the load transmission element 133 and for receiving a counterforce F2 from the counter-pressure unit 132 on a second surface 135 of the load transmission element 133. In particular, the second surface 5 135 of the load transmission element 133 may be located at an opposing side of the first surface 134 of the load transmission element 133.
[0032] According to some embodiments which can be combined with any other embodiments described herein, the load transmission element 133 may have an S-shape, e.g. as shown in FIG. 5A, or a Z-shape, e.g. as shown in FIG. 5B.0 According to an alternative implementation of the load transmission element not shown in the figures, the load transmission element may be a plate extending in an axial direction of the processing roller.
[0033] In the present disclosure, the term "pressure unit" is to be understood as a unit in which a pressure of a fluid is employed for generating a force or a5 movement. For example, a "pressure unit" as described herein may be a pneumatic unit in which a compressible fluid, particularly gas (e.g. air), is used for generating a force or a movement. Using a pneumatic unit may in particular be beneficial for vacuum processing, because a pneumatic unit automatically reacts to the pressure change during evacuation of the processing chamber. Alternatively, a "pressure0 unit" as described herein may be a hydraulic unit in which an incompressible fluid, particularly a liquid (e.g. oil or water), is used for generating a force or a movement.
[0034] Accordingly, in the present disclosure, the term "counter-pressure unit" is to be understood as a unit in which a pressure of a fluid is employed for5 generating a counter-force or a counter-movement to the force or the movement generated by the "pressure unit" as described herein. In particular, a "counter- pressure unit" may be a pneumatic unit or a hydraulic unit similar to the "pressure unit" as described herein.
[0035] With exemplary, reference to FIG. 5A, according to embodiments0 which can be combined with any other embodiments described herein, the apparatus may include a first pressure valve 151 configured for controlling a first pressure generated by the pressure unit 131. Additionally, a second pressure valve 152 configured for controlling a second pressure generated by the counter-pressure unit 132 may be provided. For example, the first pressure valve 151 and/or the second pressure valve 152 may be connected to a controller 150 which can be configured for controlling the first pressure and/or the second pressure. Accordingly, beneficially the contact pressure between doctor blades of the doctor blade assembly with the processing roller can precisely be controlled and adapted during operation of the apparatus as described herein, such that high-quality coating and printing results can be achieved.
[0036] According to embodiments which can be combined with any other embodiments described herein, the first pressure provided by the pressure unit 131 may be selected from a range having a lower limit of 2 bar, particularly a lower limit of 3 bar, more particularly a lower limit of 4 bar and having an upper limit of 4 bar, particularly an upper limit of 6 bar, more particularly an upper limit of 8 bar.
[0037] According to embodiments which can be combined with any other embodiments described herein, the second pressure provided by the counter- pressure unit 132 may be selected from a range having a lower limit of 0 bar, particularly a lower limit of 1 bar, more particularly a lower limit of 2 bar and having an upper limit of 2 bar, particularly an upper limit of 4 bar, more particularly an upper limit of 6 bar.
[0038] According to embodiments which can be combined with any other embodiments described herein, the controller 150 of the apparatus may be configured for controlling a pressure difference between the pressure unit 131 and the counter-pressure unit 132. In particular, the controller 150 may be configured for controlling the pressure difference to be constant. For example, the pressure difference may be selected from a range having a lower limit of 1 bar, particularly a lower limit of 1.5 bar and an upper limit of 3 bar, particularly 4 bar. For instance, the pressure difference between the pressure unit 131 and the counter-pressure unit 132 may be 2 bar ±0.5 bar, particularly 2 bar ±0.1 bar, more particularly 2 bar ±0.05 bar.
[0039] Accordingly, beneficially the contact pressure between doctor blades of the doctor blade assembly with the processing roller can be controlled to be constant throughout a coating or printing process, such that the contact pressure may substantially be not influenced by any changes of the ambient pressure in the processing chamber, particularly during evacuation in which the ambient pressure changes from an atmospheric pressure to a vacuum pressure. Accordingly, beneficially and initially set up contact pressure under atmospheric pressure conditions corresponds to the actual contact pressure during operation of the apparatus under vacuum conditions. Further, beneficially, by increasing the first pressure provided by the pressure unit as well as increasing the second pressure provided by the counter pressure unit the overall stability of the contact pressure between doctor blades of the doctor blade assembly with the processing roller can increased. For example, a contact pressure of 2 bar which is established by a first pressure of 8 bar by the pressure unit and a second pressure of 6 bar by the counter pressure unit may be more stable compared to a situation in which the contact pressure of 2 bar is established by a first pressure of 4 bar by the pressure unit and a second pressure of 2 bar by the counter pressure unit. [0040] According to embodiments which can be combined with any other embodiments described herein, the apparatus may further include a monitoring device for monitoring the first pressure provided by the pressure unit 131 and/or for monitoring the second pressure provided by the counter-pressure unit 132. For example, the monitoring device may be a pressure sensor. In particular, a first pressure sensor may be provided which is configured and arranged for measuring the first pressure provided by the pressure unit 131 and/or a second pressure sensor may be provided which is configured and arranged for measuring the second pressure provided by the counter-pressure unit 132. The first pressure sensor and/or the second pressure sensor may be connected to the controller as described herein. Accordingly, beneficially the controller may be configured to adjust the first pressure and/or the second pressure, e.g. in the case that a measured pressure deviates from a preselected first pressure and/or second pressure as specified herein.
[0041] Accordingly, it is to be understood that embodiments as described herein provide for automatic adaption or readjustment of the contact pressure from the doctor blades of the doctor blade assembly with the processing roller which may in particular be beneficial to compensate for abrasive wear effects of the doctor blades. Further, embodiments as described herein provide for adjusting the contact pressure of the doctor blades with the corresponding processing roller during operation of the apparatus which may be beneficial in the case that different processing conditions, particularly a different layer thickness of liquid coating or printing material, is to be selected during operation of the apparatus. Accordingly, embodiments as described herein provide for adapting and readjusting the contact pressure of doctor blades with a processing roller under vacuum conditions. In particular, the contact pressure may be controlled and adjusted without breaking an established vacuum during processing. Further, it is to be understood that embodiments described herein, particularly when the force transmission assembly includes pneumatic units, are configured to compensate for deformations of the processing roller, e.g. caused by thermal expansion.
[0042] According to embodiments which can be combined with any other embodiments described herein, the force transmission assembly 130 may include a guiding element 144 for guiding a movement of the doctor blade assembly 120 towards the surface 111 of the processing roller 110, as exemplarily shown in FIGS. 4A, 4B, 5 A and 5B. For example, the guiding element 144 may be a linear guiding element having low friction. In particular, the guiding movement may be a movement which is substantially perpendicular to the axis of the processing roller. Accordingly, beneficially the doctor blades of the doctor blade assembly as described herein can be precisely positioned onto the surface of the corresponding processing roller. Further, providing a guiding element as described herein may also be beneficial for precisely adjusting the contact pressure of the doctor blades with the corresponding surface of the processing roller. [0043] Accordingly, it is to be understood that according to embodiments which can be combined with any other embodiments described herein, the doctor blade assembly, particularly the doctor blade chamber, can be guided by the guiding element for providing a precise and guided movement of the doctor blade assembly towards the surface of the processing roller in order to provide the contact pressure.
[0044] FIGS. 6 A to 6C show block diagrams illustrating embodiments of a method 200 for providing a contact pressure of a doctor blade onto a surface of a processing roller. According to embodiments which can be combined with any other embodiments described herein, the method includes applying 210 a force on a doctor blade assembly including the doctor blade by using a pressure unit and controlling 220 the contact pressure by applying a counter-force on the doctor blade assembly by using a counter-pressure unit, as exemplary illustrated by the block diagram shown in FIG. 6A. In particular, applying 210 a force on a doctor blade assembly may include using a pressure unit according to embodiments described herein. Further, controlling 220 the contact pressure by applying a counter-force on the doctor blade assembly may include using a counter-pressure unit according to embodiments described herein. Accordingly, embodiments of the method as described herein beneficially provide for controlling and adjusting the contact pressure of a doctor blade with a surface of a processing roller very accurately. In particular, embodiments of the method as described herein provide for controlling said contact pressure substantially independent of the ambient pressure. Accordingly, with embodiments of the method as described herein, the contact pressure of the doctor blade with the surface of the processing roller can be controlled to be constant even if an ambient pressure change occurs.
[0045] According to embodiments which can be combined with any other embodiments described herein, controlling 220 the contact pressure includes generating 221 a pressure difference between a first pressure applied by the pressure unit on a load transmission element and a second pressure applied by the counter-pressure unit on the load transmission element. In particular, generating 221 the pressure difference can include applying a force Fi from the pressure unit 131 on the first surface 134 of the load transmission element 133 and applying a counterforce F2 from the counter-pressure unit 132 on the second surface 135 of the load transmission element 133.
[0046] According to embodiments which can be combined with any other embodiments described herein, generating 221 the pressure difference may include selecting the first pressure provided by the pressure from a range having a lower limit of 2 bar, particularly a lower limit of 3 bar, more particularly a lower limit of 4 bar and having an upper limit of 4 bar, particularly an upper limit of 6 bar, more particularly an upper limit of 8 bar. Further, generating 221 the pressure difference may include selecting the second pressure provided by the counter-pressure unit 132 from a range having a lower limit of 0 bar, particularly a lower limit of 1 bar, more particularly a lower limit of 2 bar and having an upper limit of 2 bar, particularly an upper limit of 4 bar, more particularly an upper limit of 6 bar.
[0047] It is to be understood that controlling 220 the contact pressure may include using a first pressure valve 151 and/or a second pressure valve 152 as described herein. In particular, controlling 220 the contact pressure may include using a controller 150 as described herein. Accordingly, embodiments of the method as described herein provide for automatic adaption or readjustment of the contact pressure from the doctor blades of the doctor blade assembly as described herein with a corresponding processing roller which may in particular be beneficial to compensate for abrasive wear effects of the doctor blades.
[0048] According to embodiments which can be combined with any other embodiments described herein, the method may include monitoring 230 the pressure difference, as exemplarily illustrated by the block diagram shown in FIG. 6B. In particular, monitoring 230 the pressure difference may include using a monitoring device, e.g. a first pressure sensor and/or the second pressure sensor, as described herein. Accordingly, embodiments of the method as described herein are configured for monitoring and adjusting a first pressure and/or a second pressure as specified herein, which may in particular be beneficial in the case that a measured pressure deviates from a preselected first pressure and/or second pressure as specified herein.
[0049] According to embodiments which can be combined with any other embodiments described herein, the method may further include controlling 240 the pressure difference to be constant such that the contact pressure of the doctor blade with the processing roller is independent of an ambient pressure. For instance, controlling 240 the pressure difference to be constant may include selecting the pressure difference from a range having a lower limit of 1 bar, particularly a lower limit of 1.5 bar and an upper limit of 3 bar, particularly 4 bar. In particular, controlling 240 the pressure difference between the pressure unit 131 and the counter-pressure unit 132 to be constant may include selecting the pressure difference to be 2 bar ±0.2 bar, particularly 2 bar ±0.1 bar, more particularly 2 bar ±0.05 bar.
[0050] In view of the embodiments as described in the present disclosure, the skilled person understands that embodiments of the apparatus as well as of the method as described herein are particularly suited for precisely adjusting and controlling a constant contact pressure of doctor blades of a doctor blade chamber with an anilox or screen roller, particularly for coating or printing of flexible substrates with a large substrate width.

Claims

1. An apparatus (100) for continuous processing of a flexible substrate in a vacuum, the apparatus comprising:
- a processing roller (110), - a doctor blade assembly (120) having a doctor blade (121) extending in an axial direction of the processing roller (110); and
- a force transmission assembly (130) configured for moving the doctor blade assembly (120) towards a surface (111) of the processing roller (110), wherein the force transmission assembly (130) comprises a pressure unit (131) for applying a force on the doctor blade assembly (120) and a counter-pressure unit (132) for applying a counter- force on the doctor blade assembly (120).
2. The apparatus (100) according to claim 1, wherein the force transmission assembly (120) comprises a load transmission element (133), wherein the load transmission element (133) is configured for transmitting a force from the pressure unit (131) to the doctor blade assembly (120) and for transmitting a counter- force from the counter-pressure unit (132) to the doctor blade assembly (120).
3. The apparatus (100) according to claim 1 or 2, further comprising a first pressure valve (151) configured for controlling a first pressure generated by the pressure unit (131) and a second pressure valve (152) configured for controlling a second pressure generated by the counter-pressure unit (132).
4. The apparatus (100) according to claim 3, wherein the first pressure is selected from 2 bar to 8 bar, and wherein the second pressure is selected from 0 bar to 6 bar.
5. The apparatus (100) according to any of claims 1 to 4, further comprising a controller (150) for controlling a pressure difference between the pressure unit (131) and the counter-pressure unit (132).
6. The apparatus (100) according to claim 5, wherein the pressure difference is constant, and particularly wherein the pressure difference is from 1 bar to 4 bar, particularly from 1.5 bar to 3 bar.
7. The apparatus (100) according to any of claims 3 to 6, further comprising a monitoring device for monitoring the first pressure and/or the second pressure.
8. The apparatus (100) according to any of claims 1 to 7, wherein the force transmission assembly (130) comprises a guiding element (140) for guiding a movement of the doctor blade assembly (120) towards the surface (111) of the processing roller (110).
9. An apparatus (100) for continuous processing of a flexible substrate in a vacuum, the apparatus comprising:
- a processing roller (110),
- a doctor blade assembly (120) having a doctor blade (121) extending in an axial direction of the processing roller (110); - a first force transmission assembly (130A) configured for moving the doctor blade (121) onto a surface of the processing roller (110), wherein the first force transmission assembly (130A) comprises a first pneumatic pressure unit (131 A) for applying a force on the doctor blade assembly and a first pneumatic counter- pressure unit (132A) for applying a counter-force on the doctor blade assembly (120), wherein the first force transmission assembly (130A) is arranged at a first axial end (120 A) of the doctor blade assembly (120),
wherein the first force transmission assembly (130A) comprises a first load transmission element (133A) connected to the doctor blade assembly (120), wherein the first load transmission element (133 A) is configured for transmitting a force from the first pneumatic pressure unit (131 A) to the doctor blade assembly (120) and for transmitting a counter-force from the first pneumatic counter-pressure unit (132A) to the doctor blade assembly (120); and - a second force transmission assembly (130B) configured for moving the doctor blade (121) onto the surface of the processing roller (110), wherein the second force transmission assembly (130B) comprises a second pneumatic pressure unit (13 IB) for applying a force on the doctor blade assembly and a second 5 pneumatic counter-pressure unit (132B) for applying a counter- force on the doctor blade assembly (120), wherein the second force transmission assembly (130B) is arranged at a second axial end (120B) of the doctor blade assembly (120) opposing the first axial end (120A) of the doctor blade assembly (120),
wherein the second force transmission assembly (130B) comprises a second 10 load transmission element (133B) connected to the doctor blade assembly (120), wherein the second load transmission element (133B) is configured for transmitting a force from the second pneumatic pressure unit (13 IB) to the doctor blade assembly (120) and for transmitting a counter- force from the second pneumatic counter-pressure unit (132B) to the doctor blade assembly (120).
15 10. A method (200) for providing a contact pressure of a doctor blade onto a surface of a processing roller, the method comprising:
- applying (210) a force on a doctor blade assembly comprising the doctor blade by using a pressure unit; and
- controlling (220) the contact pressure by applying a counter-force on the doctor 20 blade assembly by using a counter-pressure unit.
11. The method (200) according to claim 10, wherein controlling (220) the contact pressure comprises generating (221) a pressure difference between a first pressure applied by the pressure unit on a load transmission element and a second pressure applied by the counter-pressure unit on the load transmission element.
25 12. The method (200) according to claim 11, further comprising monitoring (230) the pressure difference.
13. The method (200) according to claim 11 or 12, further comprising controlling (240) the pressure difference to be constant such that the contact pressure of the doctor blade with the processing roller is independent of an ambient pressure.
14. The method (200) according to any of claims 11 to 13, wherein the first pressure is selected from 2 bar to 8 bar, and wherein the second pressure is selected from 0 bar to 6 bar.
15. The method (200) according to any of claims 11 to 14, wherein the pressure difference is selected to from 1 bar to 4 bar, particularly from 1.5 bar to 3 bar.
PCT/EP2016/061136 2016-05-18 2016-05-18 Apparatus for continuous processing of a flexible substrate in a vacuum and method therefor WO2017198296A1 (en)

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KR1020187036754A KR102224515B1 (en) 2016-05-18 2016-05-18 Apparatus for continuously processing flexible substrates in vacuum and method therefor
JP2018560603A JP6751447B2 (en) 2016-05-18 2016-05-18 Apparatus for continuous processing of flexible substrates in vacuum, and method therefor
CN201680085819.XA CN109153254B (en) 2016-05-18 2016-05-18 Apparatus for continuously processing flexible substrate in vacuum and method thereof
PCT/EP2016/061136 WO2017198296A1 (en) 2016-05-18 2016-05-18 Apparatus for continuous processing of a flexible substrate in a vacuum and method therefor
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JP6751447B2 (en) 2020-09-02
KR20190008574A (en) 2019-01-24
KR102224515B1 (en) 2021-03-05
CN109153254A (en) 2019-01-04
CN109153254B (en) 2021-06-08

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