U.S. patent application number 16/608434 was filed with the patent office on 2020-06-18 for passive edge guiding method and apparatus.
The applicant listed for this patent is 3M INNOVATIVE PROPERTIES COMPANY. Invention is credited to James N. Dobbs, Ameeta R. Goyal, Glen A. Jerry, Ronald P. Swanson.
Application Number | 20200189870 16/608434 |
Document ID | / |
Family ID | 63918933 |
Filed Date | 2020-06-18 |
![](/patent/app/20200189870/US20200189870A1-20200618-D00000.png)
![](/patent/app/20200189870/US20200189870A1-20200618-D00001.png)
![](/patent/app/20200189870/US20200189870A1-20200618-D00002.png)
![](/patent/app/20200189870/US20200189870A1-20200618-D00003.png)
![](/patent/app/20200189870/US20200189870A1-20200618-D00004.png)
United States Patent
Application |
20200189870 |
Kind Code |
A1 |
Jerry; Glen A. ; et
al. |
June 18, 2020 |
PASSIVE EDGE GUIDING METHOD AND APPARATUS
Abstract
Web handling apparatuses and methods are provided to passively
control a lateral position of a moving web. The web wraps around
support rollers adjacent opposed web edges. One or more guide
rollers are positioned adjacent to the support rollers. The guide
rollers are in rolling contact with the web edge to guide the
moving, misguided web back into its desired lateral position.
Inventors: |
Jerry; Glen A.; (Blaine,
MN) ; Swanson; Ronald P.; (Woodbury, MN) ;
Goyal; Ameeta R.; (Woodbury, MN) ; Dobbs; James
N.; (Woodbury, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
3M INNOVATIVE PROPERTIES COMPANY |
St. Paul |
MN |
US |
|
|
Family ID: |
63918933 |
Appl. No.: |
16/608434 |
Filed: |
April 20, 2018 |
PCT Filed: |
April 20, 2018 |
PCT NO: |
PCT/IB2018/052782 |
371 Date: |
October 25, 2019 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62491605 |
Apr 28, 2017 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65H 23/0322 20130101;
B65H 23/038 20130101; B65H 2701/1315 20130101; B65H 23/0324
20130101; B65H 2404/15212 20130101; B65H 27/00 20130101; B65H
2701/1752 20130101; B65H 23/00 20130101; B65H 2601/2532 20130101;
B65H 2404/14212 20130101 |
International
Class: |
B65H 23/032 20060101
B65H023/032; B65H 23/038 20060101 B65H023/038 |
Claims
1. A web handling apparatus comprising: first and second support
rollers, a web being configured to wrap around the first and second
support rollers adjacent first and second web edges thereof,
respectively, the first and second support rollers being rotatable
to move the web along a length direction thereof; and first and
second guide rollers positioned adjacent the first and second
support rollers, respectively, the first and second guide rollers
being configured to control a lateral position of the web by
contacting the respective first or second web edge along a lateral
direction thereof substantially perpendicular to the length
direction.
2. The web handling apparatus of claim 1, wherein the web wraps
around the first and second support rollers with a wrap angle of
about 90.degree. to about 230.degree..
3. The web handling apparatus of claim 1, wherein a span of the web
between the first guide roller and the first support roller has a
length of about 1 cm to about 10 cm.
4. The web handling apparatus of claim 1, wherein at least one of
the first and second guide rollers includes a groove to receive the
first or second edge of the web, the groove has opposite sides
configured to contact opposite major surfaces of the web at the
first edge.
5. The web handling apparatus of claim 1, wherein the first and
second guide rollers are positioned with a distance therebetween
substantially the same as the width of the web.
6. The web handling apparatus of claim 1, wherein the web comprises
an un-contacted region between the first and the second support
rolls comprising at least about 50% of the width of the web.
7. The web handling apparatus of claim 1 further comprises a bowed
shaft, wherein at least one of the first support roller and the
second support roller is supported on the bowed shaft such that at
least one of the first and second support rollers is angled
outwardly with respect to a direction of web travel.
8. The web handling apparatus of claim 1, wherein the first and
second support rollers are respectively angled outwardly with an
angle .theta..
9. The web handling apparatus of claim 8, wherein the angle .theta.
is adjustable in a range of about 0.degree. to about 6.degree..
10. The web handling apparatus of claim 1, wherein the first and
second guide rollers each are positioned at an upstream position of
the respective first and second support rollers.
11. An apparatus for transporting a web material, the apparatus
comprising: a first support roller positioned to contact a major
surface of a web adjacent a first edge of the web; a second support
roller positioned to contact the major surface of the web adjacent
a second edge thereof opposite the first edge; and a first guide
roller positioned adjacent the first support roller, wherein the
web wraps around the first and second support rollers adjacent the
first and second edges thereof, respectively, and wherein the first
guide roller is configured to be in rolling contact with the first
edge of the web when the web shifts laterally toward the first
guide roller.
12. The apparatus of claim 11 further comprising a second guide
roller positioned adjacent the second support roller, and the
second guide roller being configured to contact the second edge of
the web.
13. The apparatus of claim 11, wherein the first guide roller is
positioned at an upstream position of the first support roller.
14. A method comprising: wrapping a web around first and second
support rollers adjacent opposite first and second edges of the
web, respectively, the first and second support rollers being
rotatable to move the web along a length direction thereof;
providing a first guide roller adjacent the first support roller;
and adjusting the lateral position of the web by contacting the
first guide roller to the first edge of the web along a lateral
direction of the web substantially perpendicular to the length
direction.
15. The method of claim 14 further comprising providing a groove to
the first guide roller to receive the first edge of the web, the
groove has opposite sides configured to contact opposite major
surfaces of the web at the first edge.
16. The method of claim 14, wherein a central region of the web
between the first support roller and the second support roller
comprising at least about 80% of a width of the web is free of
support from a roller.
17. The method of claim 14, wherein the web wraps about the first
roller and the second roller at an angle of about 90.degree. to
about 230.degree..
18. The method of claim 14 further comprising orienting at least
one of the first and second support rollers at an angle .theta. in
a plane x-y with respect to the length direction x normal to the
width direction y of the web, and wherein the angle .theta. is
adjustable in a range of about 0.degree. to about 6.degree..
19. The method of claim 14 further comprising positioning a second
guide roller adjacent the second support roller to contact the
second edge of the web.
20. The method of claim 14 further comprising applying a coating
composition on the web, and processing the coating composition to
form a coating layer on the web.
Description
BACKGROUND
[0001] In general, a functional film can be made on a process line
by delivering an uncoated web material, applying a coating
composition to the web material, and performing drying or other
treatment steps to process the coating composition to form a
coating layer on the web material. The coating composition is often
not coated across the full width of the web material, and the
uncoated margins are eventually cut off prior to winding up the
coated web product.
[0002] Rollers can be utilized to convey the web material on the
process line. Thin web substrate materials can be particularly
difficult to transport over or between the rollers on the process
line without causing wrinkles, kinks, bagginess, and the like, and
such defects can significantly reduce the value of the coated web
product. In addition, passing very thin or delicate coatings over
and through rollers can damage the coating layer, which also
reduces the value of the coated web product to a potential
customer. Various techniques for web handling are described in, for
example, WO2013/090134 (Swanson et al.) and WO2016/106043 (Jerry et
al.).
[0003] Reducing frictional force at an interface between the
surface of the rollers and the surface of the web material can be
helpful in reducing these types of defects. For example, reducing
the tension on the web substrate material, changing the material on
the surfaces of the rollers that contacts the web substrate (for
example, using o-rings or sleeves on the contacting surfaces of the
rollers), and reducing the wrap angle at which the web substrate
contacts the roller have been employed.
SUMMARY
[0004] There is a desire to precisely control the position of a
moving web in a cross direction perpendicular to the longitudinal,
or "machine direction." Some embodiments of the apparatus disclosed
in WO2016/106043 (Jerry et al.) disclose transporting a web
substrate material over an arrangement of at least two support
rollers in which the rollers contact the web substrate material
only at opposed edges thereof. The web wraps the at least two
support rollers with a substantial wrap angle. This wrap angle is
part of what allows the positioning of rollers at opposed edges of
the web substrate material, leaving a center region of the web
substrate material substantially unsupported by the rollers. In
effect, the web material is forced into a configuration as a
partial cylinder, increasing its resistance to buckling.
[0005] The present disclosure found that this buckling resistance
can be exploited to provide a mechanism to steer the lateral edge
of the web for applications where precise positioning in the cross
web direction is required. In some embodiments, one or more guide
rollers can be positioned adjacent to the support rollers to
passively control a lateral position of a moving web: when the
guide rollers are in rolling contact with the respective web
edge(s) of the moving web along a cross-web or lateral direction,
the web can be guided to move back to its desired lateral position.
In some embodiments, the term "passive control" means that the
position of a guide roller can be fixed and achieve the objective
of moving the misguided web back into the target position by
exerting force on the edge of the web. In some embodiments, the
position of a guide roller can be pre-adjusted to be at a
predetermined position so as to be in rolling contact with the edge
of the web.
[0006] In one aspect, the present disclosure is directed to a web
handling apparatus having first and second support rollers. A web
is configured to wrap around the first and second support rollers
adjacent first and second web edges, respectively. The first and
second support rollers are rotatable to move the web along a length
direction thereof. The web handling apparatus further includes
first and second guide rollers positioned adjacent the first and
second support rollers, respectively. The first and second guide
rollers are configured to control a lateral position of the web by
contacting the respective first or second edge of the web along a
lateral direction thereof substantially perpendicular to the length
direction.
[0007] In another aspect, the present disclosure is directed to an
apparatus for transporting a web material. The apparatus includes a
first support roller positioned to contact a major surface of a web
adjacent a first edge of the web, and a second support roller
positioned to contact the major surface of the web adjacent a
second edge thereof opposite the first edge. A first guide roller
is positioned adjacent the first support roller. The web wraps
around the first and second support rollers adjacent the first and
second edges thereof, respectively. The first guide roller is
configured to be in rolling contact with the first edge of the
substrate when the web shifts laterally toward the first guide
roller.
[0008] In yet another aspect, the present disclosure is directed to
a method including wrapping a web around first and second support
rollers adjacent opposite first and second edges of the web,
respectively. The first and second support rollers are rotatable to
move the web along a length direction thereof. The method further
includes providing a first guide roller adjacent the first support
roller, and adjusting the lateral position of the web by contacting
the first guide roller to the first edge of the web along a lateral
direction of the web substantially perpendicular to the length
direction.
[0009] Various unexpected results and advantages are obtained in
exemplary embodiments of the disclosure. One such advantage of
exemplary embodiments of the present disclosure is that the lateral
position of a web can be precisely controlled without touching the
central portion of the web's major surfaces. This is accomplished
by positioning one or more guide rollers adjacent to the support
rollers. When a moving web shifts laterally from its desired
position, the one or more guide rollers can be in rolling contact
with the web edge(s) to guide the web back into its desired lateral
position.
[0010] Various aspects and advantages of exemplary embodiments of
the disclosure have been summarized. The above Summary is not
intended to describe each illustrated embodiment or every
implementation of the present certain exemplary embodiments of the
present disclosure. The Drawings and the Detailed Description that
follow more particularly exemplify certain preferred embodiments
using the principles disclosed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The disclosure may be more completely understood in
consideration of the following detailed description of various
embodiments of the disclosure in connection with the accompanying
figures, in which:
[0012] FIG. 1 is a schematic perspective view of an embodiment of a
web handling apparatus.
[0013] FIG. 2 is a schematic side view of a roller in a web
handling apparatus.
[0014] FIG. 3 is a schematic perspective view of an embodiment of a
web handling apparatus.
[0015] FIG. 4 is a schematic overhead view of a die coating system
including an embodiment of a web handling apparatus.
[0016] FIG. 5 is a schematic side view of a spray coating system
including an embodiment of a web handling apparatus.
[0017] FIG. 6 is a web material processing system including an
embodiment of a web handling apparatus.
[0018] FIG. 7A is a perspective view of a guide roller, according
to one embodiment.
[0019] FIG. 7B is a perspective view of a guide roller including a
groove, according to another embodiment.
[0020] In the drawings, like reference numerals indicate like
elements. While the above-identified drawing, which may not be
drawn to scale, sets forth various embodiments of the present
disclosure, other embodiments are also contemplated, as noted in
the Detailed Description. In all cases, this disclosure describes
the presently disclosed disclosure by way of representation of
exemplary embodiments and not by express limitations. It should be
understood that numerous other modifications and embodiments can be
devised by those skilled in the art, which fall within the scope
and spirit of this disclosure.
DETAILED DESCRIPTION
[0021] There is a desire to precisely control the position of a
moving web in a cross direction perpendicular to the longitudinal,
or "machine direction." Some embodiments of the apparatus disclosed
in WO2016/106043 (Jerry et al.) include a substantial wrap angle
around the at least two rollers which contact a substrate in the
form of a web of material of indefinite length. This wrap angle is
part of what allows the positioning the rollers at opposed edges of
the web substrate material, leaving a center region of the web
substrate material substantially unsupported by the rollers. In
effect, the web is forced into a configuration as a partial
cylinder, increasing its resistance to buckling.
[0022] The present disclosure found that this buckling resistance
can be exploited to provide a mechanism to steer the lateral edge
of the web for applications where precise positioning in the cross
web direction is required. One or more guide rollers can be
positioned adjacent to the support rollers to passively control a
lateral position of a moving web: when the guide rollers are in
rolling contact with the respective web edge(s) of the moving web
along a cross-web or lateral direction, the web can be guided to
move back to its desired lateral position.
[0023] Exemplary embodiments of the present disclosure may take on
various modifications and alterations without departing from the
spirit and scope of the present disclosure. Accordingly, it is to
be understood that the embodiments of the present disclosure are
not to be limited to the following described exemplary embodiments,
but is to be controlled by the limitations set forth in the claims
and any equivalents thereof.
[0024] Various exemplary embodiments of the disclosure will now be
described with particular reference to the Drawings. Exemplary
embodiments of the present disclosure may take on various
modifications and alterations without departing from the spirit and
scope of the disclosure. Accordingly, it is to be understood that
the embodiments of the present disclosure are not to be limited to
the following described exemplary embodiments, but are to be
controlled by the limitations set forth in the claims and any
equivalents thereof.
[0025] Referring to FIG. 1, an embodiment of a portion of a web
handling apparatus 120 is illustrated. A web material 122 with a
first edge 122a and second opposed edge 122b moves in a direction
D.sub.1. The web material 122 has a length substantially longer
than its width, and moves along its length direction. In this view,
components of the web handling apparatus 120 that are shown through
the transparent web material 122 are depicted with lines of lighter
weight for visual clarity.
[0026] The web material 122 wraps around a first support roller 130
and a second support roller 132 adjacent the first edge 122a and
the second edge 122b, respectively. The support rollers each may
have a width substantially smaller than the width of the web
material. A shaft 124 is provided to support the first roller 130
and the second roller 132. The web material 122 has its surface
portions 14 and 15 adjacent the first and second edges 122a and
122b to move over the surfaces of the support rollers 130, 132,
turns, and moves downstream of the support rollers 130, 132 in a
direction D.sub.2. In some embodiments, the surfaces of the support
rollers 130, 132 can include o-rings or sleeves to modify the
coefficient of static friction at an interface with the web
material 122. In some embodiments, the support rollers 130, 132 can
be idler rollers.
[0027] The support rollers 130 and 132 toe outwardly at angles
.theta..sub.1 and .theta..sub.2, respectively, with respect to the
direction A to produce an optimum path for the web material 122.
While not wishing to be bound by any theory, presently available
evidence indicates that the toed outward orientation of at least
one of the rollers can gently pull the web material 122 in a
web-cross or lateral direction normal to its length direction
(e.g., the direction A), which can maintain tension in the web
material 122 and help to maintain sufficient engagement between the
support rollers 130, 132 and the opposed surface portions 14 and 15
to transport the web material 122.
[0028] In the depicted embodiment, the shaft 124 is sufficiently
bowed to cause at least one of the support rollers 130, 132 to toe
outwardly. It is to be understood that the support rollers 130 and
132 can be supported by different shafts and the outward angles
.theta..sub.1 and .theta..sub.2 can be separately controlled. It
should be noted that it is not necessary that
.theta..sub.1=.theta..sub.2, and .theta..sub.1 and .theta..sub.2
can be independently selected from greater than about 0.degree. to
about 6.degree., or greater than about 0 to about 2.degree., or
greater than about 0.degree. to about 1.degree., or about
0.2.degree. to about 0.8.degree..
[0029] The shaft 124 may be bowed using any suitable mechanical
mechanism such as, for example, a push rod, a four-bar mechanism, a
cam mechanism, and the like. In the embodiment of FIG. 1, a push
rod 134, which is mounted on a support 136 and adjustable by a
suitable mechanism such as a threaded bolt 138, engages the shaft
124 and moves the shaft 124 in the direction A. The "bowing" of the
shaft 124 can be modified by adjusting the push rod 134.
[0030] The web handling apparatus 120 of FIG. 1 further includes a
first guide roller 32 and a second guide roller 34 that are shown
in contact with the first edge 122a and the second edge 122b,
respectively. The first and second guide rollers 32 and 34 are
provided to constrain the cross-web or lateral position of web
material 122 by contacting the respective first or second edge 122a
or 122b along a lateral direction thereof substantially
perpendicular to the length direction A. In some embodiments, the
guide rollers 32 and 34 can be supported by their respective shafts
(not shown) substantially perpendicular to the shaft 124.
[0031] The first and second guide rollers 32 and 34 each are
rotatable about their respective axes. See arrows 32a and 34a in
FIG. 1. The first and second guide rollers 32 and 34 each have a
contacting surface 32s or 34s positioned to be in rolling contact
with the respective first or second web edge 122a or 122b. Upon
contacting the web edges, the guide rollers 32 and 34 can rotate as
indicated by the arrows 32a and 34a. When the lateral position of
web material 122 shifts towards one side (e.g., towards the first
guide roller 32 or the second guide roller 34), the corresponding
guide roller 32 or 34 can be in rolling contact with the respective
edges 122a or 122b of the web material 122 to guide the web
material 122 to move back to its original lateral position.
[0032] The surfaces 32s, 34s of the guide rollers 32, 34 in rolling
contact the web material 122 can be independently selected from a
wide range of materials including, for example, natural and
synthetic rubber, silicone, polymeric materials, metals, and the
like. In some embodiments, the surfaces 32s, 34s of the guide
rollers 32, 34 can include o-rings or sleeves to modify the
coefficient of static friction at an interface with the web
material 122. In some embodiments, the surfaces 32s, 34s of the
guide rollers 32, 34 can be independently shaped or modified to
achieve the desired rolling contact with the web edges. Exemplary
guide rollers are shown in FIGS. 7A-B and will be described further
below.
[0033] Surprisingly the web material 122 even with a thin thickness
can endure the contact to the guide rollers 32 or 34 without
substantial bending or tearing, which may be, at least partially,
attributed to that the first 32 and second 34 guide rollers are
positioned adjacent the first 130 and second 132 support rollers,
respectively. In some embodiments, the longitudinal distance d1 or
d2 of the span of the web material 122 between the guide roller
32/34 and the support roller 130/132 may be in a range, for
example, from about 1 cm to about 10 cm. It is to be understood
that the longitudinal distance d1 or d2 may depend on other process
parameters such as, for example, the width of the web material, the
thickness of the web material, the stiffness of the web material,
the stress applied to the web material by the support rollers, the
length of the span of the web material between adjacent support
rollers along the length direction, etc. In general, the guide
rollers 32 or 34 can be positioned at any suitable distance
adjacent to the corresponding support roller as long as such
rolling contact with the web edge would not introduce any
substantial bending or tearing in the web material 122.
[0034] In the depicted embodiment, the first 32 and second 34 guide
rollers are upstream of first 130 and second 132 support rollers,
meaning that the advancing web material 122 may encounter the first
32 and second 34 guide rollers before it encounters the first 130
and second 132 support rollers. This is believed to be a more
convenient positioning, but placement of guide rollers downstream
of the support rollers 130 and 134 is considered to be within the
scope of this disclosure.
[0035] In some embodiments, one or a pair of first guide rollers
can be positioned upstream of the support rollers; one or a pair of
second guide rollers can be positioned downstream of the support
rollers. This configuration can facilitate running web both
forwards and backwards. It might be desirable to place guide
rollers at the web entrance and web exit of each idler roller so
that a guide roller can be always positioned at the end of the web
span entering the idler roller, no matter which direction the web
may be travelling.
[0036] In some embodiments, the first and second guide rollers 32
and 34 are positioned such that a distance between the contacting
surfaces 32s, 34s is substantially the same as the width of the web
material 122. In some embodiments, the distance between the
contacting surfaces 32s, 34s may be slightly greater than the width
of the web material 122 with a predetermined tolerance T, which may
be in the range, for example, from about 0.1 mm to about 10 cm. Any
possible lateral shift of the moving web material 122 can be
constrained to be smaller than the tolerance T.
[0037] It is not necessary that embodiments of apparatus 120 within
the scope of the present disclosure have both guide rollers 32 and
34. In some embodiments, only one of the guide rollers 32, 34 is
provided to be positioned adjacent to the corresponding support
roller 130 or 132. At least one of the support rollers 130, 132 can
be adjusted such that a tension can be maintained in the web
material 122 to prevent it from shifting laterally toward one
direction. For example, in some embodiments, angles .theta..sub.1
and .theta..sub.2 may be chosen to impart a slight bias towards a
single guide roller (32, say) which can alone locate the position
of the corresponding edge (122a).
[0038] In the depicted embodiment of FIG. 1, the pair of support
rollers 130 and 132 are provided to pull the web material 122 in
the lateral direction and maintain tension in the web material 122
when it turns around the support rollers 130 and 132. At least one
of the guide rollers 32 and 34 is positioned to be in rolling
contact with the edges of the moving web material 122 when the web
material 122 shifts laterally from its desired position. Regarding
the longitudinal position of the guide roller(s), it can be
positioned adjacent to the corresponding support roller where a
sufficient web tension is maintained to prevent any substantial
bending or tearing in the web material caused by the rolling
contact. It is to be understood that any mechanisms that can
supplement or replace the support roller(s) to provide suitable web
tension can be used.
[0039] Referring to FIG. 2, a schematic side view of the embodiment
of FIG. 1 is illustrated so as to clarify what is meant by wrap
angle. The web material 122 moving in the direction D1, contacts
the first roller 130 of FIG. 1 at a first point A, wraps at an
angle .beta. around the circumference of the first roller 130, and
then separates from the first roller 130 at a point B to turn and
move in the direction D2. In various embodiments, wrap angles of
about 90.degree. to about 230.degree. have been found to be
suitable, depending on the nature of the web material 122 and
process conditions.
[0040] In another embodiment shown in FIG. 3, a portion of a web
handling apparatus 200 includes a roller 230 mounted on a shaft
224. The shaft 224 is mounted to or part of a roller support 250.
The shaft 224 is angularly adjustable through a pivot point 252
between the roller support 250 and a structural mounting element
254. As shown schematically in FIG. 3, the shaft 224 can move
through a wide range of angles .alpha. in a plane including a
longitudinal axis of the shaft 224 along a direction y and a
direction of travel x of a web material 222. In other embodiments
not shown in FIG. 3, the shaft 224 could also be made angularly
adjustable through a range of angles above or below the plane
including the longitudinal axis y of the shaft 224 and the
direction of travel x of the web material 222. As the shaft 224 is
adjusted through the angles .alpha., the angle of contact between
the roller 230 mounted thereon and the web material 222 also
changes, and the shaft 224 can be adjusted to produce a desired
contact angle between the roller 230 and the web material 222. As
shown in FIG. 3, the shaft 224 can be adjusted such that an edge
222a of the web material approaching the first contacting roller
230 and moving in direction D.sub.1 upstream of the roller 230
turns about the roller 230 and moves in a direction D.sub.2
downstream of the roller 230 without wrinkling, creasing or
bunching.
[0041] Various configurations of support roller are described in
WO2016/106043 (Jerry et al.), "Edge Contact Substrate Transport
Method and Apparatus," where the support rollers contact the web
substrate material only at opposed edges thereof. Positioning the
rollers at opposed edges of the web substrate material leaves a
center region of the web substrate material between the opposed
edges that is un-contacted by the rollers and remains substantially
unsupported by the rollers. WO2016/106043 (Jerry et al.) is hereby
incorporated by reference as if rewritten.
[0042] The web handling apparatus 200 of FIG. 3 further includes a
guide roller 36 that is shown in contact with the web edge 222a.
The guide roller 36 is provided to constrain the cross-web or
lateral position of web material 222. In some embodiments, the
guide roller 222a can be supported by a shaft substantially
perpendicular to the mounting element 254.
[0043] The guide roller is rotatable about its axis. See arrow 36a
in FIG. 3. The guide roller 36 has a contacting surface 36s to
contact the web edge 222a. Upon contacting the web edge, the guide
roller 36 can rotate as indicated by the arrow 36a. When the
lateral position of web material 222 shifts towards the first guide
roller 36, the guide roller 36 can contact the web edges 222a,
rotate, and guide the web material 222 to move back to its original
lateral position.
[0044] The web handling apparatuses described above can be used in
a wide variety of web material processing operations. For example,
a portion of a roll-to-roll web material processing system 750
depicted in FIG. 4 includes a web material handling apparatus 700
and a coating die 752. In the web handling apparatus 700, a web
material 722 moves in a direction A and traverses an arrangement of
support rollers 712, 714. The support rollers 712, 714 rotate about
a shaft 720. At least one of the support rollers 712, 714 is toed
outward and positioned at an angle .theta. in a plane x-y with
respect to a direction x normal to a longitudinal axis y of the
shaft 720. In the embodiment of FIG. 4, the support roller 712 is
angled at an angle .theta..sub.1 and the support roller 714 is
angled at an angle .theta..sub.2 with respect to the direction x.
In various embodiments, it is not necessary that
.theta..sub.1=.theta..sub.2, and .theta..sub.1 and .theta..sub.2
can be independently selected from greater than about 0.degree. to
about 6.degree., or greater than about 0 to about 2.degree., or
greater than about 0.degree. to about 1.degree., or about
0.2.degree. to about 0.8.degree.. As the web material 722 traverses
the support rollers 712, 714, the coating die 752 deposits a
coating composition 753 on a surface 725 of the web material 722 to
form a coating layer 755 thereon.
[0045] The web handling apparatus 700 further include guide rollers
732 and 734 to provide web lateral position control in the cross
web direction y. The guide rollers 732 and 734 may have similar
structures as the guide rollers 32 and 34 of FIG. 1, and configured
to control a lateral position of the web material 722 by contacting
the edges of the web along the cross-web or lateral direction
thereof, while rotating about their respective axes.
[0046] In another example shown in FIG. 5, a roll-to-roll web
material processing system 850 includes a web material handling
apparatus 800 and a spray coater 852. The web handling system 800
includes a set of support rollers 802. A web material 822 wraps
around the set of support rollers 802 at the opposite web edges
thereof. The set of support rollers 802 may have a similar
configuration as the support rollers of FIG. 1 or 3. A guide roller
832 is positioned adjacent to one of the support rollers 802, and
configured to control a lateral position of the web material 822 by
contacting the adjacent web edge along the cross-web direction
(e.g., into the paper).
[0047] As the web material 822 traverses guide roller 832 and
roller 802, the spray coater 852 deposits a coating composition 853
on a surface 825 of the web material 822 to form a coating layer
855 thereon. The processing system 850 shown schematically in FIG.
5 is particularly well suited to deposition of very thin coating
layers 855 or deposition of coating compositions on very delicate
web materials 822, or both. While not wishing to be bound by any
theory, presently available evidence suggests that reducing the
number and width of rollers underlying the web material 822 can
reduce or substantially prevent damage to sensitive coatings or
wrinkling and creases in very thin web materials.
[0048] In another example shown in FIG. 6, a roll-to-roll web
material processing system 950 includes a web material handling
apparatus 900 in a multi-chamber deposition apparatus 960. The web
material handling apparatus 900 includes a first set of drive
rollers 902 and a second set of drive rollers 904. At least one
roller in the first set of drive rollers 902 and the second set of
drive rollers 904 is bowed outward at an angle selected from
greater than about 0.degree. to about 6.degree., or greater than
about 0 to about 2.degree., or greater than about 0.degree. to
about 1.degree., or about 0.2.degree. to about 0.8.degree.. The web
handling system 900 further includes a first set of idler rollers
980 and a second set of idler rollers 982, each arranged to turn a
web material 922. The web material 922 wraps around the rollers
902, rolls 980 and 982 at opposite travelling web spans, and
rollers 904. The sets of rollers 980 and 982 can be respectively
angled outwardly in a manner similar as shown in FIG. 1.
[0049] The deposition chamber apparatus 960 includes a first
deposition chamber 961, a third deposition chamber 963, and a
second deposition chamber 962 between the first deposition chamber
961 and the third deposition chamber 963. The deposition chambers
961, 962, 963 are substantially isolated from one another. The
second deposition chamber houses the first set of drive rollers 902
and the second set of drive rollers 904. The first deposition
chamber 961 houses the first arrangement of idler rollers 980 and
the third deposition chamber 963 houses the second arrangement of
idler rollers 982.
[0050] In some embodiments, a first coating composition enters the
first deposition chamber 961 at the first deposition chamber inlet
991A and exits the first deposition chamber outlet 991B. As the web
material 922 enters the first deposition chamber 961, the first
coating composition contacts a surface 925 of the web material 922
to form a coating layer thereon (not shown in FIG. 6). Following
deposition of the first coating composition on the surface 925, the
web material 922 then enters the second deposition chamber 962,
which in some embodiments contains an inert gas input via a second
deposition chamber inlet 992A. A second coating composition enters
the third deposition chamber 963 at the third deposition chamber
inlet 993A and exits the third deposition chamber outlet 993B. The
web material enters the third deposition chamber 963 and the second
coating composition is applied on the first coating layer forms a
coating layer overlying the first coating layer. The web material
then traverses the second deposition chamber 962 and the first
deposition chamber 961 a predetermined number of additional times
forming additional layers of the first coating composition and the
second coating composition before the completed coated article is
wound up on the second set of rollers 904 in the second deposition
chamber.
[0051] In another embodiment, the first coating composition and the
second coating composition may react to form a coating layer on the
surface 925.
[0052] The web material handling apparatus 900 further includes one
or more guide rollers configured to passively guide the cross-web
or lateral position of the moving web material 922. In the depicted
embodiment of FIG. 6, one or a pair of first guide rollers 932a are
positioned adjacent to the idler roller 980a, configured to be in
rolling contact with the edge(s) of the moving web material 922;
one or a pair of second guide rollers 932b are positioned adjacent
to the idler roller 982a, configured to be in rolling contact with
the edge(s) of the moving web material 922. Positioning in the
cross-web direction can be accomplished via the one or more guide
rollers (e.g., 932a and 932b in the illustrated embodiment).
[0053] In some embodiments, it might be most effective to position
one or a pair of support rollers at the end of the web span
approaching the respective idler rollers 980 or 982, in a similar
manner as shown in FIG. 1. For example, for the web travelling in
the direction indicated by the arrows on 902, 904, the guide
roller(s) 932a are positioned as the web approaches the idler
roller 980a. A similarly positioned guide roller would be placed on
each of the idler rollers 980, 982.
[0054] In some embodiments, it might be desirable to place guide
rollers at both the web entrance and web exit of each idler roller
so that a guide roller can be always positioned at the end of the
web span entering the idler roller, no matter which direction the
web may be travelling. For example, when the web travels backwards
in a direction opposite to the direction as indicated by the arrows
on 902, 904, the guide roller(s) 932b are positioned as the web
approaches the idler roller 982a. A similarly positioned guide
roller would be placed on each of the idler rollers 980, 982.
[0055] In another embodiment, the web handling apparatuses
described above may be useful in inspection systems. Since the
rollers described herein used have a width that is narrow relative
to the width of the web material, the web material is less likely
to be distorted by contacting a wide roller or system of rollers,
and debris on the rollers is less likely to contaminate the sample
being inspected.
[0056] Referring now to FIGS. 7A-B, exemplary guide rollers
described herein are shown, according to some embodiments. FIG. 7A
illustrates a guide roller 30 that is rotatable about its axis and
has a periphery surface 30s. A bearing 35 is provided to support
the guide roller 30 in rolling contact with a web edge. When the
guide roller 30 is in rolling contact with a web edge (e.g., 122a
or 122b in FIG. 1), the periphery surface 30s contacts the web edge
along a cross-web or lateral direction to control a lateral
position of the web. In some embodiments, the periphery surface 30s
can be shaped or modified to optimize the rolling contact to the
web edge.
[0057] In the embodiment of FIG. 7B, a groove 33 is formed into the
periphery surface 30s of a guide roller 30' to receive and further
support the edge of the web against folding or buckling. The groove
33 has first and second opposite sides, 33a and 33b, and a bottom
surface (not visible in FIG. 7B). The guide roller 30' is rotatable
about its axis. The bearing 35 to support the guide roller 30' in
rolling contact with a web edge can also be seen. When the guide
roller 30' is in rolling contact with a web edge, the web edge
(e.g., 122a or 122b in FIG. 1) can contact the bottom surface of
the groove 33. The sides 33a or 33b of the groove 33 may contact
the surface portions of the web received by the groove 33 to
prevent possible folding or buckling. The size of the groove 33 may
depend on the desired application. In some embodiments, the groove
33 may have a depth, for example, from about 1 mm to 100 mm, from
about 3 mm to 50 mm, or from about 5 mm to 30 mm; the groove 33 may
have a width, for example, from about 5 mm to 100 mm, from about 10
mm to 50 mm, or from about 15 mm to 30 mm.
[0058] The web handling apparatuses described herein may be used to
process web materials at a wide variety of web speeds from about 5
feet per minute (about 13 cm/sec) to about 3000 feet per minute
(about 76 m/sec), and may be used in any surrounding medium
including air, inert gases, water, vacuum and the like.
[0059] In some embodiments, a control system may optionally be used
to control and/or maintain the toe out angle of the rollers.
[0060] The operation of the present disclosure will be further
described with regard to the following detailed example(s). These
example(s) are offered to further illustrate the various specific
and preferred embodiments and techniques. It should be understood,
however, that many variations and modifications may be made while
remaining within the scope of the present disclosure.
Example
[0061] These Examples are merely for illustrative purposes and are
not meant to be overly limiting on the scope of the appended
claims. Notwithstanding that the numerical ranges and parameters
setting forth the broad scope of the present disclosure are
approximations, the numerical values set forth in the specific
examples are reported as precisely as possible. Any numerical
value, however, inherently contains certain errors necessarily
resulting from the standard deviation found in their respective
testing measurements. At the very least, and not as an attempt to
limit the application of the doctrine of equivalents to the scope
of the claims, each numerical parameter should at least be
construed in light of the number of reported significant digits and
by applying ordinary rounding techniques.
[0062] A web handling apparatus was constructed generally as
depicted in FIG. 1 with support rollers spaced apart at a distance
of 14 inches (35.56 cm) and used to transport web material in the
form of a web of indefinite length. Several runs were made with
polyethylene terephthalate (PET) of different thicknesses,
specifically 0.13 mm, 0.076 mm, and 0.051 mm. The rollers were toed
out at an angle of about greater than about 0.degree. to about
6.degree., or greater than about 0 to about 2.degree., or greater
than about 0.degree. to about 1.degree., or about 0.2.degree. to
about 0.8.degree. as shown in FIG. 1. A web tension of 10
pound-force was applied across the span of the web (1.25 N/linear
cm). Guide rollers having a diameter of 1.75 inches (4.45 cm) and
possessing a groove having a width of 0.605 inch (1.54 cm) and a
depth of 0.25 inch (0.64 cm) were positioned 2.5 inches (6.4 cm)
upstream of the support rollers, such that the web was retained
within the groove. The web was advanced at a speed of 100 feet/min
(30.5 m/min). In spite of the thinness of the web and the length of
the unsupported span between the support rollers, the web was
conveyed smoothly and without buckling. Further, the contact with
the guide rollers was maintained without folding or buckling, such
that the cross web position of the web was constrained to a high
degree of certainty.
Listing of Exemplary Embodiments
[0063] Various embodiments of the present disclosure have been
described. These and other embodiments are within the scope of the
following claims.
[0064] Embodiment A is directed to a web handling apparatus
comprising:
[0065] first and second support rollers, a web being configured to
wrap around the first and second support rollers at first and
second web edges, respectively, the first and second support
rollers being rotatable to move the web along a length direction
thereof; and
[0066] first and second guide rollers positioned adjacent the first
and second support rollers, respectively, the first and second
guide rollers being configured to control a lateral position of the
web by contacting the respective first or second edge of the web
along a lateral direction thereof substantially perpendicular to
the length direction.
[0067] Embodiment B is directed to the web handling apparatus
according to Embodiment A, wherein the web wraps around the first
and second support rollers with a wrap angle of about 90.degree. to
about 230.degree..
[0068] Embodiment C is directed to the web handling apparatus
according to Embodiments A or B, wherein a span of the web between
the first guide roller and the first support roller has a length of
about 1 cm to about 10 cm.
[0069] Embodiment D is directed to the web handling apparatus
according to any of the preceding Embodiments A-C, wherein at least
one of the first and second guide rollers includes a groove to
receive the first or second edge of the web, the groove having
opposite sides configured to contact opposite major surfaces of the
web at the first edge.
[0070] Embodiment E is directed to the web handling apparatus
according to any of the preceding Embodiments A-D, wherein the
first and second guide rollers are positioned with a distance
therebetween substantially the same as the width of the web.
[0071] Embodiment F is directed to the web handling apparatus
according to any of the preceding Embodiments A-E, wherein the web
comprises an un-contacted region between the first and the second
support rolls comprising at least about 50% of the width of the
web.
[0072] Embodiment G is directed to the web handling apparatus
according to any of the preceding Embodiments A-F, wherein at least
one of the first support roller and the second support roller is
supported on the bowed shaft such that at least one of the first
and second support rollers is angled outwardly with respect to a
direction of web travel.
[0073] Embodiment H is directed to the web handling apparatus
according to any of the preceding Embodiments A-G, wherein the
first and second support rollers are respectively angled outwardly
with an angle .theta..
[0074] Embodiment I is directed to the web handling apparatus
according to Embodiment H, wherein the angle .theta. is adjustable
in a range of about 0.degree. to about 6.degree..
[0075] Embodiment J is directed to the web handling apparatus
according to any of the preceding Embodiments A-I, wherein the
first and second guide rollers each are positioned at an upstream
position of the respective first and second support rollers.
[0076] Embodiment K is directed to an apparatus for transporting a
web material, the apparatus comprising:
[0077] a first support roller positioned to contact a major surface
of a web adjacent a first edge of the web;
[0078] a second support roller positioned to contact the major
surface of the web adjacent a second edge thereof opposite the
first edge; and
[0079] a first guide roller positioned adjacent the first support
roller,
[0080] wherein the web wraps around the first and second support
rollers adjacent the first and second edges thereof, respectively,
and wherein the first guide roller is configured to be in rolling
contact with the first edge of the substrate when the web shifts
laterally toward the first guide roller.
[0081] Embodiment L is directed to an apparatus for transporting a
web material according to embodiment K, further comprising a second
guide roller positioned adjacent the second support roller, and
configured to contact the second edge of the substrate.
[0082] Embodiment M is directed to an apparatus for transporting a
web material according to embodiments K or L, wherein the first
guide roller is positioned at an upstream position of the first
support roller.
[0083] Embodiment N is directed to a method comprising: wrapping a
web around first and second support rollers adjacent opposite first
and second edges of the web, respectively, the first and second
support rollers being rotatable to move the web along a length
direction thereof;
[0084] providing a first guide roller adjacent the first support
roller; and
[0085] adjusting the lateral position of the web by contacting the
first guide roller to the first edge of the web along a lateral
direction of the web substantially perpendicular to the length
direction.
[0086] Embodiment O is directed to the method according to
Embodiment N, further comprising providing a groove to the first
guide roller to receive the first edge of the web, the groove has
opposite sides configured to contact opposite major surfaces of the
web at the first edge.
[0087] Embodiment P is directed to the method according to
Embodiments N or O, wherein a central region of the web between the
first support roller and the second support roller comprising at
least about 80% of a width of the web is free of support from a
roller.
[0088] Embodiment Q is directed to the method according to
Embodiments N-P, wherein the web wraps about the first roller and
the second roller at an angle of about 90.degree. to about
230.degree..
[0089] Embodiment R is directed to the method according to
Embodiments N-Q, further comprising orienting at least one of the
first and second support rollers at an angle .theta. in a plane x-y
with respect to the length direction x normal to the width
direction y of the web, and wherein the angle .theta. is adjustable
in a range of about 0.degree. to about 6.degree..
[0090] Embodiment S is directed to the method according to
Embodiments N-R, further comprising positioning a second guide
roller adjacent the second support roller to contact the second
edge of the web.
[0091] Embodiment T is directed to the method according to
Embodiments N-S, further comprising applying a coating composition
on the web, and processing the coating composition to form a
coating layer on the web.
[0092] Reference throughout this specification to "one embodiment,"
"certain embodiments," "one or more embodiments" or "an
embodiment," whether or not including the term "exemplary"
preceding the term "embodiment," means that a particular feature,
structure, material, or characteristic described in connection with
the embodiment is included in at least one embodiment of the
certain exemplary embodiments of the present disclosure. Thus, the
appearances of the phrases such as "in one or more embodiments,"
"in certain embodiments," "in one embodiment" or "in an embodiment"
in various places throughout this specification are not necessarily
referring to the same embodiment of the certain exemplary
embodiments of the present disclosure. Furthermore, the particular
features, structures, materials, or characteristics may be combined
in any suitable manner in one or more embodiments.
[0093] While the specification has described in detail certain
exemplary embodiments, it will be appreciated that those skilled in
the art, upon attaining an understanding of the foregoing, may
readily conceive of alterations to, variations of, and equivalents
to these embodiments. Accordingly, it should be understood that
this disclosure is not to be unduly limited to the illustrative
embodiments set forth hereinabove. In particular, as used herein,
the recitation of numerical ranges by endpoints is intended to
include all numbers subsumed within that range (e.g., 1 to 5
includes 1, 1.5, 2, 2.75, 3, 3.80, 4, and 5). In addition, all
numbers used herein are assumed to be modified by the term
"about."
[0094] Furthermore, all publications and patents referenced herein
are incorporated by reference in their entirety to the same extent
as if each individual publication or patent was specifically and
individually indicated to be incorporated by reference. Various
exemplary embodiments have been described. These and other
embodiments are within the scope of the following claims.
* * * * *