초록 ▼

A method for forming a coating layer is provided according to the invention. The method includes steps of assembling a die coater comprising a first die block (12), a second die block (14), and a plurality of fasteners (40) holding the first die block and the second die block together, wherein each

A method for forming a coating layer is provided according to the invention. The method includes steps of assembling a die coater comprising a first die block (12), a second die block (14), and a plurality of fasteners (40) holding the first die block and the second die block together, wherein each of the plurality of fasteners provides a compression force between the first die block and the second die block, and the first die block and the second die block are constructed to provide an internal manifold (16) and a coating slot (18), and extruding a coating material through the internal manifold and the coating slot. The coating slot can be adjusted to provide a more uniform coating slot along the length of the coating slot by adjusting the compression force of the fasteners, utilizing an offset bracket (80), adjusting the die bolt locations, adjusting the die overhang, providing a non-uniform shim (30), or a combination thereof. A die coater is additionally described.

대표청구항 ▼

I claim: 1. A die coater comprising a first die block, a second die block, and a plurality of fasteners holding the first die block and the second die block together, wherein: (a) each of the plurality of fasteners extends through the first die block, into the second die block, and provides a compr

I claim: 1. A die coater comprising a first die block, a second die block, and a plurality of fasteners holding the first die block and the second die block together, wherein: (a) each of the plurality of fasteners extends through the first die block, into the second die block, and provides a compression force between the first die block and the second die block; (b) the first die block and the second die block are constructed to provide an internal manifold and a coating slot; and (c) some of said fasteners are located behind the internal manifold, where the term behind is with reference to the die face being considered the front of the die coater, and are arranged so that some are rearward fasteners and some are forward fasteners, the forward fasteners being closer to the coating slot of the die than the rearward fasteners, said die coater characterized in that: the fasteners of part (c) comprise a forward row of fasteners and a rearward row of fasteners in which OF refers to the distance between a forward fastener and the internal manifold, OB refers to the distance between the rearward fastener and the die back surface, and the forward and rearward fasteners are spaced symmetrically so that the value of OF is approximately the same as OB ; at least two of said fasteners, one rearward fastener and the forward fastener nearest said rearward fastener, have a torque differential of greater than about 5%; the die coater has an overhang OH, defined as the linear distance along the first die block surface facing the coating slot of the die from the rear of the die manifold to the leading edge of the die slot, of less than about 119 mm; the cube of the ratio of overhang to the thickness of the first die block is less than about 9; and the quantity defined by the cube of the ratio of the overhang/thickness divided by the modulus of elasticity of the first die block is less than about 3.0×10−7 in2/lb (4.35×10−5 Mpa−1). 2. A die coater, comprising a first die block, a second die block, and a plurality of fasteners holding the first die block and the second die block together, wherein: (a) each of the plurality of fasteners extends through the first die block, into the second die block, and provides a compression force between the first die block and the second die block; (b) the first die block and the second die block are constructed to provide an internal manifold and a coating slot; and (c) some of said fasteners are located behind the internal manifold, where the term behind is with reference to the die face being considered the front of the die coater, and are arranged so that some are rearward fasteners and some are forward fasteners, the forward fasteners being closer to the coating slot of the die than the rearward fasteners, said die coater further comprising an offset bracket for adjusting the compression force between at least one forward fastener and at least one rearward fastener both of which are located behind the internal manifold and extend through the offset bracket, said offset bracket comprising a forward leg, a rearward leg, an offset arm and having an opening between the forward and rearward legs, the offset arm extending forward of the forward leg, rearward of the rearward leg or being between the forward and rearward legs, and characterized in that at least two of said fasteners, one rearward and the forward fastener nearest said rearward fastener, have a torque differential of greater than about 3%. 3. A die coater according to claim 2, wherein the coating slot has a height uniformity of within about 1.5%. 4. A die coater according to claim 2, wherein the coating slot has a height uniformity of within about 1%. 5. A die coater comprising a first die block, a second die block, and a plurality of fasteners holding the first die block and the second die block together, and an offset bracket comprising a forward leg, a rearward leg, an offset arm and having an opening between the forward and rearward legs, the offset arm extending forward of the forward leg, rearward of the rearward leg or being between the forward and rearward legs, wherein: (a) each of the plurality of fasteners extends through the first die block, into the second die block, and provides a compression force between the first die block and the second die block; and (b) the first die block and the second die block are constructed to provide an internal manifold and a coating slot; and (c) some of said fasteners are located behind the internal manifold, where the term behind is with reference to the die face being considered the front of the die coater, are arranged so that some are rearward fasteners and some are forward fasteners, forward fasteners being closer to the coating slot than the rearward fasteners, and at least one of said fasteners extends through a forward leg or a rearward leg of the offset bracket and at least one fastener extends through the offset arm and not through a forward or rearward leg, for distributing the compression force between the first die block and the second die block differently than would be provided without the offset bracket. 6. The die coater according to claim 5, for which certain parameters are defined as OFis the distance between the forward fastener extending through the offset bracket and the internal manifold, OBis the distance between the rearward fastener extending through the offset bracket and the back surface of the die SBis the center-to-center distance between the forward and rearward fasteners, Tfront is the torque on the forward fastener, and Tback is the torque on the rearward fastener, and the relationship of Tfront to Tback is defined by the following equation T front = T back ⁡ ( S B + O F - O B S B - O F - O B ) . 7. A die coater according to claim 5, wherein the coating slot has a height uniformity of within about 1%. 8. A die coater according to claim 5, wherein at least two of the plurality of fasteners have a torque difference of greater than about 3%. 9. A die coater comprising a first die block, a second die block, and a plurality of fasteners holding the first die block and the second die block together, wherein: (a) each of the plurality of fasteners extends through the first die block, into the second die block, and provides a compression force between the first die block and the second die block; (b) the first die block and the second die block are constructed to provide an internal manifold and a coating slot; (c) the die coater has an overhang OH, defined as the linear distance along the first die block surface facing the coating slot of the die from the rear of the die manifold to the leading edge of the die slot, of less than about 119 mm; and (d) the die coater is characterized by a cube of the ratio of overhang to thickness of the first die block of less than about 9; and (e) the quantity defined by the cube of the ratio of the overhang/thickness divided by the modulus of elasticity of the first die block is less than about 3.0×10−7 in2/lb (4.35×10−5Mpa−1).