You are on page 1of 4

¡ÜGap Coating (Knife Over Roll, Kinfe Over Blanket, Floating Knife, etc.

) This process relies on a coating being applied to the substrate which then passes through a 'gap' between a 'knife' and a support roller. As the coating and substrate pass through, the excess is scraped off. This process can be used for high viscosity coatings and very high coat weights, such as plastisols and rubber coatings. There are innumerable variants of the relatively simple process which is rugged, hard working and somewhat inaccurate.
a. !oating compound b. !oating knife c. "acking roll #$%& 'nife over roll. a. (ndless blanket b. !oating compound c. !oating knife #$)& 'nife over blanket. a. *dler roll b. !oating compound c. +hoe d. !oating knife e. "acking roll #$,& -loating knif.

. ¡Ü Reverse Roll Coating *n this procedure, the coating material is measured onto the applicator roller by precision setting of the gap between the upper metering roller and the application roller below it. The coating is 'wiped' off the application roller by the substrate as it passes around the support roller at the bottom. The diagram illustrates a , roll reverse roll coating process, although / roll versions are common. *n 0everse 1ravure !oating, the actual coating material is metered by the engraving on a roller before being wiped off as in a conventional reverse roll coating process.
a. 2octor knife b. Transfer roll c. "acking roll d. !oating compound #$%& 3 head reberse roll coater. a. 4etering gap

a. 2octor e. This process is fre8uently used on porous substrates. 2octor blade b. . The excess coating on the roller is wiped off by the 2octor "lade and the coating is then deposited onto the substrate as it passes between the (ngraved roller and a 6ressure 0oller. a.& 6an fed reverse roll coater. a. . where the coating is deposited on an intermediate roller before transfer to the substrate. 2octor blade d. Transfer roll #$)& 5ip fed reverse roll coater. ¡ÜGravure Coating The gravure coating process relies on an engraved roller running in a coating bath. Applicator roll c. which is normally of a low viscosity to enable the coating to run back into the bath as the substrate emerges. +teel roll b. *dler roll b. !hemical compound #$. "acking roll c. Immersion ( ip) Coating *n this simple process. "acking roll d. the substrate is dipped into a bath of the coating. 2octor h. 5ip rolls . a. 0eservoir plate g. 0ubber roll c. which fills the engraved dots or lines of the roller with the coating material. !oating compound f. a. . (lastomeric d. 9ffset 1ravure is common. "acking roll c. 4etering roll d. -abric in b. This procedure is typically used for a8ueous coatings and is particularly noisy. 4etering roll e. (ngraved rotofravure roll #$)& 9ffset engraved roll coater.b. !oating roll #$%& Air kinfe coater. Air knife b. ¡ÜAir Knife Coating A simple process where the coating is applied to the substrate and the excess is 'blown off' by a powerful 7et from the air knife. (ngrabed otofravure roll #$%& (ngraved roll coater. *nd pan c.

0ubber pressure roll c. allows the desired 8uantity of the coating to remain on the substrate. :ire wound rod d. To oven #$%& !urtain coater. 0eturn idler e. (xtrusion die #$%& 4elt extrusion coater. ¡Ü Curtain Coating *n the !urtain !oating process. *f the coating is %<<= solids. ¡Ü $lot ie ($lot. Ad7ustable idler b. a. This process is remarkably tolerant of non precision engineering of the other components of the coating machine. ¡Ü Rotar# $creen A puddle of coating solution sits inside a cylindrical screen which is pierced by holes where it is desired that the coating is 'extruded'. :ire wound rod #$%& :ire wound rod coater.c. 9ut e. -abric in b. sometimes known as a 4eyer "ar. A s8ueegee pushes the solution through these holes as the cylinder rotates in contact with the substrate. -abric in b. the coating is s8uee. 9ut #$%& 2ip coater. This enables coatings to be considerably thinner than the width of the slot. .ed out by gravity or under pressure through a slot and onto the substrate. a. . !omplicated patterns are possible> screens . a. . 6resssure die d. Applicator roll c. %&trusion) Coating *n the +lot 2ie process. The 8uantity is determined by the diameter of the wire used on the rod. a bath with a slot in the base allows a continuous curtain of the coating to fall into the gap between two conveyors. the line speed is fre8uently much faster than the speed of the extrusion. an excess of the coating is deposited onto the substrate as it passes over the bath roller. The ob7ect to be coated. !hill roll d. such as a door. ¡Ü !etering Ro" (!e#er Bar) Coating *n this coating process. is passed along the conveyor at a controlled speed and so receives the coating on its upper face. !ompound in sheet form e. +melly and crude versions of these machines were once common. The wire wound metering rod. the process is termed '(xtrusion' and in this case. . +upport rolls c.

4olten polymer #$%& !alender.. +pray no. ¡Ü $pra# Coating a. -abric in b. lack of drying tunnel etc. !ompound spray e. +upport rolls c. . . . ¡Ü Calen"ar Coating a. ¡Ü Foam Coating . . @ot melt where possible brings tremendous advantages in terms of speed. 4uch used for making wallcoverings. *n a small number of cases the desired coating can be melted and applied while hot. . Applicator roll c. -abric in b. To over d. the low viscosity re8uired to achieve an even coating is achieved by solution or dispersion. These are hotmelt processes.le assembly #$%& +pray coating. The main limitation is the small number of applications for which suitable coatings are available. ¡Ü Cast Coating a. 9ut #$%& !ast coater. . 4ost of these are adhesives.are expensive> repeat lengths may be problematic. ¡Ü 'ot !elt Coating *n most of the coatings appled commercially. ¡Ü Roll coating #$%& 0oll coater. . !ompound d. The actual coating techni8ues used are still one of those listed below? so there is hot melt slot die> hot melt metering rod> etc. -abric in b.