METHOD AND SYSTEM FOR ADJUSTING A DRYING PROCESS DESIGNATED FOR PRODUCING A COATING

Abstract

A computer-implemented method and system for adjusting at least one drying process designated for producing at least one coating on at least one substrate are provided herein. The at least one drying process is applied to at least one preparation deposited on the at least one substrate, wherein the at least one drying process comprises at least two consecutive drying stages after which the at least one coating is produced Further disclosed are a related method and system for continuously producing the at least one coating on the at least one substrate.

Claims

1. A computer-implemented method for adjusting at least one drying process designated for producing at least one coating on at least one substrate, wherein the at least one drying process is applied to at least one preparation deposited on the at least one substrate, wherein the at least one drying process comprises at least two consecutive drying stages after which the at least one coating is produced, wherein the method comprises: (i) receiving information about a layout of the at least two consecutive drying stages, about a composition of the preparation, and about the at least one substrate; (ii) employing at least one model configured to generate at least one predictive value for at least one setting parameter for at least one associated dryer being used during at least one of the drying stages; (iii) determining the at least one predictive value for the at least one setting parameter for the at least one associated dryer being used during the at least one of the drying stages based on the at least one model and the information; and (iv) providing at least one recommended procedure for adjusting the at least one drying process which comprises the at least one predictive value for the at least one setting parameter for the at least one associated dryer suitable for being used during the at least one of the drying stages.

2. The computer-implemented method according to claim 1, wherein the at least one model is generated by using at least one known value for the at least one setting parameter for the at least one associated dryer being used during the at least one of the drying stages, wherein the at least one known value for the at least one setting parameter for the at least one associated dryer is acquired in at least one test drying process comprising at least one test layout of the at least two consecutive drying stages.

3. The computer-implemented method according to claim 1, wherein the at least one model is based on at least one of a composition of the preparation, at least one parameter related to at least one property of at least one component of the preparation, at least one measured value for at least one material parameter related to the at least one coating after the at least two drying stages, at least one known influence on crack formation in the at least one coating, and at least one value for an energy consumption as a consequence of the at least one setting parameter for the at least one associated dryer being used during at least one of the drying stages.

4. The computer-implemented method according to claim 3, wherein the at least one material parameter related to the at least one coating after the at least two drying stages is selected from at least one parameter related to at least one of an adhesion of the at least one coating on the at least one substrate and a performance of the at least one coating in at least one application.

5. The computer-implemented method according to claim 3, wherein the at least one model is generated by applying an optimizing procedure in which it is intended to increase at least one value of the at least one parameter related to at least one of an adhesion of the at least one coating on the at least one substrate and of the performance of the at least one coating in at least one application and to decrease at least one value for the at least one known influence on crack formation in the at least one coating and the at least one value for an energy consumption.

6. The computer-implemented method according to claim 1, wherein the consecutive drying stages comprise at least one initial drying stage and at least one critical drying stage following the at least one initial drying stage, wherein the at least one setting parameter for the at least one associated dryer is adjusted during the at least one critical drying stage to differ from the at least one setting parameter for the at least one associated dryer as adjusted during the at least one initial drying stage.

7. The computer-implemented method according to claim 6, further comprising at least three consecutive drying stages, wherein the at least three consecutive drying stages further comprise at least one final drying stage following the at least one critical drying stage, wherein the at least one setting parameter for the at least one associated dryer during the at least one final drying stage is adjusted to differ from the at least one setting parameter for the at least one associated dryer as adjusted during the at least one critical stage.

8. The computer-implemented method according to claim 1, wherein the at least one recommended procedure comprises adjusting the at least one setting parameter for the at least one associated dryer to a constant value during the at least one drying stage.

9. The computer-implemented method according to claim 1, wherein the at least one setting parameter for the at least one associated dryer comprises at least one of an individual temperature profile and an individual heat transfer profile during the at least one drying stage.

10. The computer-implemented method according to claim 9, wherein the at least one recommended procedure comprises adjusting at least one of the individual temperature profile by setting at least one temperature control unit and the individual heat transfer profile by setting at least one blowing unit.

11. The computer implemented method according to claim 1, further comprising providing the information about a layout of the at least two consecutive drying stages, about a composition of the preparation, and about the at least one substrate and receiving the at least one recommended procedure for adjusting the at least one drying process which comprises the at least one predictive value for the at least one setting parameter for the at least one associated dryer suitable for being used during the at least one of the drying stages.

12. The computer-implemented method according to claim 1, wherein the producing of the at least one coating on the at least one substrate is performed in a continuous manner by continuously depositing the at least one preparation onto the at least one substrate, wherein at least one tape is or comprises the at least one substrate, or wherein the at least one tape carries the at least one substrate, wherein the at least one tape is moved during the at least two consecutive drying stages with a tape speed, wherein the at least one model is further configured to generate a predictive value for the tape speed, wherein the predictive value for the tape speed is further determined, and wherein the at least one recommended procedure for adjusting the at least one drying process further comprises outputting the predictive value for the tape speed.

13. A system for adjusting at least one drying process designated for producing at least one coating on at least one substrate, the system comprising: at least one processing unit, wherein the at least one processing unit is configured to perform a computer-implemented method for adjusting at least one drying process designated for producing at least one coating on at least one substrate, wherein the at least one drying process is applied to at least one preparation deposited on the at least one substrate, wherein the at least one drying process comprises at least two consecutive drying stages after which the at least one coating is produced, wherein the method comprises: (i) receiving information about a layout of the at least two consecutive drying stages, about a composition of the preparation, and about the at least one substrate; (ii) employing at least one model configured to generate at least one predictive value for at least one setting parameter for at least one associated dryer being used during at least one of the drying stages; (iii) determining the at least one predictive value for the at least one setting parameter for the at least one associated dryer being used during the at least one of the drying stages based on the at least one model and the information; and (iv) providing at least one recommended procedure for adjusting the at least one drying process which comprises the at least one predictive value for the at least one setting parameter for the at least one associated dryer being used during the at least one of the drying stages; at least one communication interface configured to receive the information according to step (i); and at least one further communication interface configured to provide the at least one recommended procedure for adjusting the at least one drying process according to step (iv).

14. A system for adjusting at least one drying process designated for producing at least one coating, the system comprising: at least one component of at least one preparation to be used in at least one drying process, wherein the at least one drying process comprises at least two consecutive drying stages after which at least one coating is produced by using the at least one component; and at least one recommended procedure for adjusting the at least one drying process, wherein the at least one recommended procedure comprises at least one predictive value for at least one setting parameter for at least one associated dryer being used during the at least one of the drying stages.

15. A method for continuously producing at least one coating on at least one substrate, the method comprising: a) introducing at least one tape into a coating device, wherein the coating device is configured to move the at least one tape with a tape speed through at least one application area and at least two consecutive drying zones, wherein each drying zone; comprises at least one associated dryer, wherein the coating device is further configured to adjust at least one of the tape speed and at least one setting parameter for the at least one associated dryer in each drying zone; b) depositing at least one preparation onto at least one side of at least one substrate in the at least one application area, wherein the at least one tape is or comprises the at least one substrate, or wherein the at least one tape carries the at least one substrate; c) employing at least one model configured to generate at least one predictive value for the tape speed and for the at least one setting parameter for at least one associated dryer in the at least one of the drying zones based on information about a layout of the at least two drying zones, about a composition of the preparation, and about the at least one substrate; d) determining the at least one predictive value for at least one of the tape speed and the at least one setting parameter for the at least one associated dryer in the at least one of the drying zones based on the at least one model and the information; e) adjusting the at least one drying process by using at least one recommended procedure which comprises the at least one predictive value for at least one of the tape speed and the at least one setting parameter for the at least one associated dryer in the at least one of the drying zones; and f) drying the at least one preparation within the at least two consecutive drying zones, whereby the at last one coating is obtained.

16. A system for continuously producing at least one coating on at least one substrate, the system comprising: a coating device, wherein the coating device comprises at last one conveyor drive configured to move at least one tape with a tape speed; at least one application area configured to provide at least one preparation to be deposited onto at least one side of the tape; and at least two consecutive drying zones configured to dry the at least one preparation, wherein each drying zone comprises at least one associated dryer; at least one programmable apparatus, wherein the at least one programmable apparatus is configured to: (i) receive information about a layout of the at least two consecutive drying zones, about a composition of the preparation, about the at least one substrate, and about the tape speed; (ii) employ at least one model configured to generate at least one predictive value for at least one of the tape speed and at least one setting parameter for at least one associated dryer being used within at least one of the drying zones; (iii) determine the at least one predictive value for at least one of the tape speed and the at least one setting parameter for the at least one associated dryer within the at least one of the drying zones based on the at least one model and the information; and (iv) provide at least one recommended procedure for adjusting the at least one drying process which comprises the at least one predictive value for at least one of the tape speed and the at least one setting parameter for the at least one associated dryer within the at least one of the drying zones; and at least one control unit configured to interact with the at least one programmable apparatus; and to control the coating device by adjusting the at least one drying process by implementing at least one recommended procedure.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0179] Further optional details and features of the invention are evident from the description of preferred exemplary embodiments which follows in conjunction with the dependent Embodiments. In this context, the particular features may be implemented alone or in any reasonable combination. The invention is not restricted to the exemplary embodiments. The exemplary embodiments are shown schematically in the figures. Identical reference numerals in the individual figures refer to identical elements or elements with identical function, or elements which correspond to one another with regard to their functions.

[0180] In the Figures:

[0181] FIG. 1 illustrates a preferred embodiment of a system for producing a coating on both sides of a tape;

[0182] FIG. 2 illustrates drying profiles of differently designed drying processes over time;

[0183] FIGS. 3A to 3D illustrate experimental results obtained by adjusting the at least one drying process according to the present invention;

[0184] FIG. 4 illustrates a preferred embodiment of a computer-implemented method for adjusting at least one drying process designated for producing at least one coating on at least one substrate; and

[0185] FIG. 5 illustrates a preferred embodiment of a system for adjusting at least one drying process designated for producing at least one coating on at least one substrate.

EXEMPLARY EMBODIMENTS

[0186] FIG. 1 schematically illustrates a preferred embodiment of a system 110 for producing a coating 112, 112′ on one or both sides 114, 114′ of a tape 116, wherein each side 114, 114′ of the tape 116 may function as a substrate 118,118′ for the respective coating 112, 112′. As an alternative, a separate substrate (not depicted here) can be carried by one or both sides 114, 114′ of the tape 116, wherein the coating 112, 112′ may be applied to separate substrate, respectively.

[0187] The system 110 according to the present invention comprises a coating device 120. Herein, the coating device 120 has a conveyor drive which is configured to move the tape 116 with a tape speed 122. As schematically depicted in FIG. 1, the conveyor drive comprises a first drum 124 which carries and provides the uncoated tape 116 and a second drum 124′ which receives the coated tape 116. In general, it is sufficient that the first drum 124 may be powered to move the tape 116 forward with the desired tape speed 122 while the second drum 124′ may functions as an unpowered idle drum. However, further kinds of arrangements of the conveyor drive may also be conceivable.

[0188] Further, the coating device 120 as schematically illustrated in FIG. 1 has two individual application areas 126, 126′, wherein each application area 126, 126′ comprises an individual coating unit 128, 128′ which is configured to provide a preparation that is deposited onto each side 114, 114′ of the tape 116 which functions as the respective substrate 118,118′. However, a different number or arrangement of the applications areas 126, 126′ may also be feasible. By way of example, a single application area 126 for producing only a single coating 112 on a single side 114 of the tape 116 may also be possible. As a further example, at least two applications areas 126, 126′ may be used for consecutively depositing at least two individual coatings 112, 112′ on the same side 114 of the tape 116. In general, the preparation as well as the number and the particular arrangement of the application areas 126, 126′ depend on the envisaged application of the coating 112, 112′. By way of example, the preparation may be used for producing a coating 112, 112′ on one or both sides 114, 114′ of the tape 116 which is designated for being used in a battery electrode. As a further example, the preparation may be used for producing a coating 112, 112′ on one or both sides 114, 114′ of the tape 116 which is be designated for being used in a photoactive layer in a solar cell. However, further examples are conceivable. The two individual application areas 126, 126′ as comprised by the coating device 120 depicted in FIG. 1 are arranged in a fashion that the second application area 126′ deposits the preparation on the second side 114′ of the tape 116 after the coating 112 on the first side 114 of the tape 116, which has been produced by depositing the preparation on the first side 114 of the tape 116, has already been dried in a first drying process.

[0189] Further, the coating device 120 as schematically illustrated in FIG. 1 has three consecutive drying zones 130, 130′, 130″ after each individual application area 126, 126′. However, for sake of simplicity only the three consecutive drying zones 130, 130′, 130″ after the first application area 126 are described below in more detail, wherein the details are mutatis mutandis applicable to the three consecutive drying zones 130, 130′, 130″ after the second application area 126 # as also depicted in FIG. 1. Each drying zone 130, 130′, 130″ after the first application area 126 is configured to dry the preparation which has been deposited in the first application area 126 by using the first coating unit 128. For this purpose, each drying zone 130, 130′, 130″ comprises an associated dryer 132, 132′, 132″, wherein at least one setting parameter for each associated dryer 132, 132′, 132″ can be set in order to adjust the drying process. In particular, the at least one setting parameter for each associated dryer 132, 132′, 132″ may comprise at least one of an individual temperature profile and an individual heat transfer profile which may be applied within the corresponding drying zone 130, 130′, 130″.

[0190] For this purpose, each drying zone 130, 130′, 130″ may comprise at least one temperature control unit (not depicted here) which is configured to set an individual temperature profile in the corresponding drying zone 130, 130′, 130″, specifically by controlling at least one of a heating unit or a cooling unit (not depicted here). As defined above, the individual temperature profile relates to a course of the temperature prevailing at the preparation within the corresponding drying zone 130, 130′, 130″, wherein the temperature may, specifically, refer to a temperature at an accessible surface of the at least one preparation as applied on the substrate 118, 118′.

[0191] In addition, each drying zone 130, 130′, 130″ may, further comprise at least one blowing unit (not depicted here) which is configured to adjust an individual heat transfer profile in the corresponding drying zone 130, 130′, 130″. As defined above, the individual heat transfer profile refers to a course of the heat transfer applied to the preparation within the corresponding drying zone 130, 130′, 130″, wherein the heat transfer may, especially, refer to a transfer of heat above the accessible surface of the at least one preparation.

[0192] In this manner, each drying zone 130, 130′, 130″ can, preferably, be addressed individually, preferably in a fashion that at least one value for the setting parameter for the associated dryer 132′ located in a particular drying zone 130′ differs from at least one value for the setting parameter for the associated dryers 132, 132″ located in adjacent drying zones 130, 130″. This advantage allows an individual setting of drying conditions in each drying zone 130, 130′, 130″ as described above and below in more detail.

[0193] As further schematically illustrated in FIG. 1, the coating device 120 may, in addition, have a sensor unit 134 which comprises at least one sensor being configured to record at least one measured value for at least one material parameter of the coating 112, 112′ after the three consecutive drying zones 130, 130′, 130″. Herein, the at least one material parameter of the coating 112, 112′ on the substrate 118, 118′ may be used for improving the at least one drying process at constant or, preferably, increasing efficiency of the drying process. In particular, the sensor unit 134 may comprise an optical sensor 136, specifically an infrared sensor, which is configured to measure a temperature at a surface of the coating 112, 112′. Alternatively or in addition, the sensor unit 134 may comprise an ultrasonic sensor 138 which is configured to measure a coating weight per area of the coating 112, 112′. However, further kinds of sensors, such as the sensors as mentioned above, may also be feasible.

[0194] In general, the at least one material parameter of the coating 112, 112′ may depend on the nature and application of the coating 112, 112′. By way of example, the coating 112, 112′ on one or both sides 114, 114′ of the tape 116 can be a coating which is designated for being used in a battery electrode. Herein, the at least one material parameter can, preferably, be selected from a peel strength of the coating 112, 112′ on the substrate and an electrode performance of the coating 112, 112′ in an application of the battery electrode in an electrochemical cell. As a further example, the coating 112, 112′ on one or both sides 114, 114′ of the tape 116 can be designated for being used in a solar cell, wherein the at least one material parameter can be selected here from a peel strength of the coating 112, 112′ on the substrate and an electrical performance of the coating 112, 112′ in an application of the solar cell in a photovoltaic solar panel. However, further examples are feasible.

[0195] According to the present invention, the system 110 for producing the coating 112, 112′ on one or both sides 114, 114′ of the tape 116 further comprises a programmable apparatus 140. As schematically depicted in FIG. 1, the programmable apparatus 140 can be or comprise a mobile communication device 142, specifically a smartphone 144. However, a further kind of programmable apparatus, such as a computer or a computer network, or a different kind of mobile communication device, can also be used for the purposes of the present invention. However, to facilitate reading of the following passage, the particular embodiment of FIG. 1 is explained on the example of the smartphone 144, wherein the details as explained are mutatis mutandis applicable to a further kind of programmable apparatus, specifically, a computer or a computer network, or a different kind of mobile communication device.

[0196] As schematically illustrated in FIG. 1, the smartphone 144 comprises a processing unit 146 which is configured to drive the smartphone 144, in particular by running one or more applications (“apps”), wherein at least one application may be configured to determine at least one output value based on at least one input value. As further depicted here, the smartphone 144 comprises a storage unit 148 which is configured to store at least one computer program, in particular at least one computer program which drives the model that is configured to generate a simulation of the drying process as explained above and below in more detail and at least one value, in particular at least one of the output value, the input value, or a value as used in the at least one computer program. As further illustrated in FIG. 1, the smartphone 144 comprises a screen 150, wherein the screen 150 comprises a virtual keypad 152 which may be configured to receive at least one input value, especially for being processed in the processing unit 146 and/or for being stored in the storage unit 148. However, as described below in more detail, the at least one input value can, alternatively or in addition, be received via at least one different channel.

[0197] In accordance with the present invention, the smartphone 144 is configured to receive information about a layout of the at least two consecutive drying stages 130, 130′, 130″, about a composition of the preparation, about the substrate 118, 118′, and about the tape speed 122. However, at least one further piece of information may, additionally, be received by the smartphone 144. As schematically illustrated in FIG. 1, information 154 about the composition of the preparation, information 156 about the substrate 118, 118′, information 158 about the layout of the at least two consecutive drying stages 130, 130′, 130″, and information 160 about the tape speed 122 can be displayed on the screen 150, specifically, to inform a user about the information 154, 156, 158, 160, to allow the user to review the information 154, 156, 158, 160 and, if applicable, to correct the information 154, 156, 158, 160, in particular, by using the virtual keypad 152.

[0198] In further accordance with the present invention, the smartphone 144 is further configured to employ at least one model which is configured to generate a predictive value 162 for the tape speed 122 and a predictive value 164 for the at least one setting parameter for each associated dryer 132, 132′, 132″ as used within the drying zones 130, 130′, 130″.

[0199] In further accordance with the present invention, the smartphone 144 is further configured to determine the predictive values 162, 164 for the tape speed 122 and for the at least one setting parameter for each associated dryer 132, 132′, 132″ as used within the drying zones 130, 130′, 130″, respectively, based on the at least one model as employed above and the information 154, 156, 158, 160 as further received above.

[0200] In further accordance with the present invention, the smartphone 144 is further configured to provide a recommended procedure 166 for adjusting the drying process. In the embodiment as schematically depicted in FIG. 1, the recommended procedure 166 comprises the predictive values 162, 164 for the tape speed 122 and for the at least one setting parameter for each associated dryer 132, 132′, 132″ as used within the drying zones 130, 130′, 130″, respectively. As already indicated above, the storage unit 148 of the smartphone 144 is further configured to store the at least one computer program which drives the model that is configured to generate a simulation of the drying process. As defined above, the model is configured to generate the predictive values 162, 164 by using the at least one computer program that is configured to generate a simulation of the drying process, wherein the drying process comprises the three consecutive drying stages 130, 130′, 130″ as used in the coating device 120 of FIG. 1. Specifically, the simulation is closely be based on the information 154 about the composition of the preparation, the information 156 about the substrate 118, 118′, the information 158 about the layout of the at least two consecutive drying stages 130, 130′, 130″, and the information 160 about the tape speed 122 as received by the smartphone 144 as described above.

[0201] In particular, the model may be generated by using known values for the composition of the preparation, the substrate 118, 118′, the layout of the consecutive drying stages 130, 130′, 130″, the tape speed 122, the at least one setting parameter for each associated dryer 132, 132′, 132″ and for at least one material parameter of the coating 112, 112′ on the substrate 118, 118′, specifically a peel strength indicating an adhesion of the coating 112, 112′ on the substrate 118, 118′. Herein, the known values may, preferably, be acquired in at least one test drying process by using at least one known preparation on at least one known substrate which comprises at least one test layout in a test coating device and one test tape speed. As a result of the test drying process, at least one relationship may be generated, wherein the at least one relationship may, for a particular preparation on a particular substrate to be dried in a particular layout as comprised by a particular coating device, refer to a plurality of values for the at least one material parameter of the coating 112, 112′ on the substrate 118, 118′, specifically the peel strength which indicates the adhesion of the coating 112, 112′ on the substrate 118, 118′, for a plurality of setting parameters of the associated dryer 132, 132′, 132″ within the corresponding drying zones 130, 130′, 130″ and the tape speed 122. As illustrated below in FIG. 3B, the at least one relationship may be displayed as at least one diagram, wherein the at least one diagram may, especially, depict the relationship between the peel strength and both the individual temperature profile and the individual heat transfer profile as applied within during the corresponding the corresponding drying zones 130, 130′, 130″ to the particular preparation on the particular substrate.

[0202] In further accordance with the present invention, the recommended procedure 166 as provided by the smartphone 144 can initiate the user to alter the tape speed 122 and/or the at least one setting parameter for each associated dryer 132, 132′, 132″ as used within the drying zones 130, 130′, 130″ in the coating device 120, specifically in a manual fashion. However, as further shown in FIG. 1, the system 110 may, in addition, comprise at least one communication interface 168 which may, especially, be configured to exchange information between the smartphone 144 and a control unit 170 as further comprised by the system 110. Herein, the at least one communication interface 168 may comprise a wire-bound element or a wireless element. By way of example, the wire-bound element may be selected from at least one of a metal wire, such as a copper wire or a gold wire; a computer bus system, such as a universal serial bus (USB); or an optical fiber, whereas the wireless element may comprise a wireless transmitter or a Bluetooth element. However, further kinds of communication interfaces may also be feasible. Preferably, the communication interface 168 may be arranged as a bidirectional communication interface configured to transmit, in one direction, the information 154, 156, 158, 160 from the control unit 170 to the smartphone 144 and to transmit, in the other direction, the recommended procedure 166 to the control unit 170.

[0203] As schematically depicted in FIG. 1, the control unit 170 may comprise at least one further processing unit 172, a storage unit 174, a monitor 176, a keyboard 178, and a plurality of interfaces 180. Herein, the at least one further processing unit 172 may be configured to drive the coating device 120, especially by using the plurality of interfaces 180. Herein, one or more, preferably all, of the interfaces 180 may be arranged as a bidirectional communication interface which is configured to forward at least one piece of data into one of two directions, or vice versa. In particular, the interfaces 180 can be used as bidirectional communication interfaces, preferably, in one direction, for transmitting instructions from the control unit 170 to at least one of the drums 124, 124′, the coating units 128, 128′, dryers 132, 132′, 132″, or the sensor unit 134, and, in the other direction, for transmitting messages from at least one of the drums 124, 124′, the coating units 128, 128′, dryers 132, 132′, 132″, or the sensor unit 134 to the control unit 170, such as data items, measurement values, or error messages. Further, the storage unit 174 may, in particular, be configured to store any one of these data items, measurement values, or error messages which can, especially, be displayed by the monitor 176, while the keyboard 178 may, specifically, be designated for inputting at least one of these instructions and/or for correcting any one of these data items, measurement values, or error messages. In particular, the control unit 170 may be configured to interact with the smartphone 144, preferably via the communication interface 168, and, further, to control the coating device 120, preferably via the plurality of interfaces 180, by adjusting the at least one drying process by implementing the recommended procedure 166.

[0204] FIG. 2 shows a diagram 210, which illustrates drying profiles 212, 214, 216 of differently designed drying processes. For this purpose, a solvent volume fraction φ is plotted over time tin φ for the different drying profiles 212, 214, 216. Accordingly, the drying profile 212 which may also be denoted by the term “rough drying profile” illustrates a particular embodiment of the drying profile in which a considerably high evaporation rate (here r=3 g/m.sup.2s) may be applied to the preparation. Although the drying profile 212 may be interesting from an economic point of view, in particular, due to a reduced drying time 218, it, generally, does not provide a desired quality of the coating 112, 112′, which can be derived from records of measured values for at least one material parameter of the coating 112, 112′ after completion of the drying process.

[0205] Therefore, in order to increase the quality of the coating 112, 112′, the drying profile 214 also denoted by the term “mild dying profile” can be used in which a low high evaporation rate (here r=1 g/m.sup.2s) may be applied to the preparation, and which provides the desired values for the at least one material parameter of the coating 112, 112′ after completion of the drying process, however, on cost of a particularly increased drying time 220. For both drying profiles 212, 214 a constant value for the setting parameters for the associated dryers 132, 132′, 132″ is being used during all drying zones 130, 130′, 130″ involved.

[0206] In accordance with the present invention, the recommended procedure 166 is provided, as described above, to adjust drying process by setting the tape speed 122 and/or the at least one setting parameter for each associated dryer 132, 132′, 132″ used within the drying zones 130, 130′, 130″ as comprised by the coating device 120. As illustrated in FIG. 2, the drying process can be partitioned into three consecutive drying stages 222, 224, 226. In this preferred exemplary embodiment, the drying process can, thus, be partitioned into an initial drying stage 222, a critical drying stage 224 following the initial drying stage 222, and a final drying stage 226 which follows the critical drying stage 224. Further, one or more of the drying stages 222, 224, 226 may be partitioned onto more than one of the drying zones 130, 130′, 130″.

[0207] As can be derived from FIG. 2, the evaporation rate of drying profile 216 also denoted by the term “partitioned drying profile” follows the evaporation rate of the rough drying profile 212 during the initial drying stage 222, applies the evaporation rate of the mild drying profile 214 during the critical drying stage 224, and returns to the evaporation rate of the rough drying profile 212 during the final drying stage 226. Herein, the drying profiles 212, 214, 216 during the corresponding drying stages 222, 224, 226 can be obtained by a setting the tape speed 122 and the at least one respective setting parameter for each associated dryer 132, 132′, 132″ in each drying zone 130, 130′, 130″ of the coating device 120. Preferably, the initial drying stage 222 may be performed herein in the first drying zone 130, the critical drying stage 224 in the successive drying zone 130′, and the final drying stage 226 in the final drying zone 130″.

[0208] As a result, the drying process according to the partitioned drying profile 216 can be performed in an intermediate drying time 228 which, certainly, exceeds the drying time 218 as required for the rough drying profile 212 but which is still below the drying time 220 as required for the mild drying profile 214, by approximately 40% in this preferred exemplary embodiment, wherein a quality of the coating 112, 112′ as obtained by applying the partitioned drying profile 216 equals the quality of the coating 112, 112′ as obtained by applying the mild dying profile 214, which can be demonstrated by recording measured values for at least one material parameter of the coating 112, 112′ after completion of the drying process according to the partitioned drying profile 216.

[0209] Not wishing to be bound by theory, the results as presented in the diagram 210 of FIG. 2 can be explained by taking into account that the preparation which is applied to the substrate 118, 118′ at the beginning of the drying process comprises at least two different components, i.e. a matrix having a plurality of at least one solid component, wherein the at least one solid component may comprise a plurality of at least one of crystalline particles, amorphous particles or dissolved molecules, and a solvent having at least one second component, wherein the at least one solvent may be selected from at least one of a liquid, a gas, or a mixture thereof. In addition, the preparation may, further, comprise at least one additional component, in particular at least one binder designated to maintain the solid components within the matrix together. In order to form the coating 112, 112′ during the drying process, a combination of particle consolidation, binder migration and solvent evaporation occurs over the three consecutive drying stages 222, 224, 226. In general, immediately after having applied the preparation onto the substrate 118, 118′, the drying process, typically, starts with the initial drying stage 222 which comprises a shrinkage of a volume of the preparation on the substrate 118, 118′, mainly due to a combination of particle consolidation and solvent evaporation from the matrix. As illustrated in FIG. 2, a value for the solvent volume fraction is reduced from φ≈0.6 to φ≈0.4 during the initial drying stage 222. Thereafter, the critical stage 224, typically, begins when the shrinkage of the volume of the preparation on the substrate 118, 118′ ends and the solvent evaporation from pores between the consolidated particles starts. As experimentally demonstrated, it may, thus, be preferred to apply the mild drying profile 216 during the critical drying stage 224 (This is why the term “critical” is used for this drying stage.) to adequately support procedures which take place during the critical drying phase 224 in order to obtain a high quality of the coating 112, 112′ within as little time as possible. As further illustrated in FIG. 2, the value for the solvent volume fraction is reduced from φ≈0.4 to φ≈0.15 during the critical drying stage 224. During the final drying stage 226, the value for the solvent volume fraction is, eventually, reduced to φ≈0, wherein the considerably high evaporation rate of the rough drying profile 212 can be used, especially in order to reduce the drying time 228 as far as possible.

[0210] FIGS. 3A to 3D illustrate experimental results which have been obtained by adjusting the at least one drying process according to the present invention.

[0211] FIG. 3A displays a course 310 of the temperature T.sub.D in ° C. and a course 312 of the heat transfer coefficient α in W/m.sup.2.Math.K as the setting parameters being used for each associated dryer 132, 132′, 132″ in each drying zone 130, 130′, 130″ in order to implement the drying stages 222, 224, 226 for a particular drying process.

[0212] FIG. 3B displays a diagram 314 which illustrates experimental results for normalized a 90° peel strength p (see standard ASTM D6862 for a description of the analytical method) of the coating 112, 112′ as a function of the individual temperature profile Tin ° C. and the individual heat transfer profile α in W/m.sup.2.Math.K as applied during the critical drying stage 224 measured for a coating weight per area w≈78.5 g/m.sup.2. Herein, a first point 316 in the diagram 314 indicates an example for suboptimal conditions T≈120° C. and α≈60 W/m.sup.2.Math.K as used for the drying procedure whereas a second point 318 in the diagram 314 indicates a further example for optimal conditions T≈80° C. and α≈30 W/m.sup.2.Math.K used for the drying procedure according to the present invention as illustrated in FIG. 3A. The diagram 314 can be considered as results which constitute a model for the particular drying process as presented in FIG. 3A.

[0213] FIG. 3C displays a course 320 of the coating weight per area w in kg/m.sup.2 of the preparation and a course 322 of the temperature T.sub.F in ° C. at a surface of the preparation in each drying zone 130, 130′, 130″ implementing the drying stages 222, 224, 226. Herein, the measured values of the course 322 of the temperature T.sub.F at the surface of the preparation have been recorded by using an optical sensor while the measured values of the course 320 of the coating weight per area w of the preparation have been recorded by using the ultrasonic sensor.

[0214] FIG. 3D displays a course 324 of the solvent volume fraction φ and a course 326 of an evaporation rate r in g/m.sup.2.Math.s in each drying zone 130, 130′, 130″ implementing the drying stages 222, 224, 226. As illustrated there, the evaporation rate is particularly reduced in the drying zone 130′ which largely corresponds to the critical stage 224.

[0215] FIG. 4 schematically illustrates a preferred embodiment of a computer-implemented method 410 for adjusting the drying process designated for producing the coating 112, 112′ on the substrate 118, 118′. As already described above, the drying process is applied to the preparation deposited on the substrate 118, 118′, wherein the drying process comprises the three consecutive drying stages 222, 224, 226 after which the coating 112, 112′ is produced. According to the present invention, the method 410 comprises the following steps.

[0216] In a receiving step 412 according to step (i), the information 154, 156, 158 about the layout of the at least two consecutive drying stages 222, 224, 226, about the composition of the preparation, and about the at least one substrate 118, 118′ is received.

[0217] In a employing step 414 according to step (ii), the at least one model is employed, wherein the at least one model is configured to generate the predictive values 162, 164 for the at least one setting parameter for each associated dryer 132, 132′, 132″ as being used during the drying stages 222, 224, 226.

[0218] In a determining step 416 according to step (iii), the predictive values 162, 164 for the at least one setting parameter for each associated dryer 132, 132′, 132″ as being during the three drying stages 222, 224, 226 is determined based on the at least one model as employed in the employing step 414 and the information 154, 156, 158 as received in the receiving step 412.

[0219] In a providing step 418 according to step (iv), the recommended procedure 166 for adjusting the drying process is provided, wherein the recommended procedure 166 comprises the predictive values 162, 164 for the at least one setting parameter for each associated dryer 132, 132′, 132″ during the three drying stages 222, 224, 226.

[0220] FIG. 5 schematically illustrates a preferred embodiment of a system 420 for adjusting the drying process designated for producing the coating 112, 112′ on the substrate 118, 118′. As depicted in FIG. 5, the system 420 comprises the processing unit 146 which is configured to perform the computer-implemented method 410 for adjusting the drying process designated for producing the coating 112, 112′ on the substrate 118, 118′ as already described above.

[0221] Further, the system 420 comprises the bidirectional communication interface 168 which is configured to function, on one hand, as a first communication interface configured to receive the information 154, 156, 158 about the layout of the at least two consecutive drying stages 222, 224, 226, about the composition of the preparation, and about the at least one substrate 118, 118′, and, on the other hand, as a further communication interface configured to provide the recommended procedure 166 for adjusting the drying process, which comprises the predictive values 162, 164 for the at least one setting parameter for each associated dryer 132, 132′, 132″ during the three drying stages 222, 224, 226, to the further processing unit 172 as comprised by the control unit 170 configured to control the coating device 120.

[0222] As further illustrated In FIG. 5, the system 420 may, in addition, comprises at least one additional communication interface 422 which may be configured to provide the recommended procedure 116, in particular, including the predictive values 162, 164, to a user, especially, via the screen 150. Alternatively or in addition, the recommended procedure 166 can be provided to the user via a different device, such as a loudspeaker (not depicted here).

LIST OF REFERENCE NUMBERS

[0223] 110 system for continuously producing at least one coating on at least one substrate [0224] 112, 112′ coating [0225] 114, 114′ side [0226] 116 tape [0227] 118, 118′ substrate [0228] 120 coating device [0229] 122 tape speed [0230] 124, 124′ drum [0231] 126, 126′ application area [0232] 128, 128′ coating unit [0233] 130, 130′, 130″ drying zone [0234] 132, 132′, 132″ associated dryer [0235] 134 sensor unit [0236] 136 optical sensor [0237] 138 ultrasonic sensor [0238] 140 programmable apparatus [0239] 142 mobile communication device [0240] 144 smartphone [0241] 146 processing unit [0242] 148 storage unit [0243] 150 screen [0244] 152 virtual keypad [0245] 154 information [0246] 156 information [0247] 158 information [0248] 160 information [0249] 162 predictive value [0250] 164 predictive value [0251] 166 recommended procedure [0252] 168 (bidirectional) communication interface [0253] 170 control unit [0254] 172 further processing unit [0255] 174 storage unit [0256] 176 monitor [0257] 178 keyboard [0258] 180 interface [0259] 210 diagram [0260] 212 rough drying profile [0261] 214 mild drying profile [0262] 216 partitioned drying profile [0263] 218 drying time [0264] 220 drying time [0265] 222 initial drying stage [0266] 224 critical drying stage [0267] 226 final drying stage [0268] 228 drying time [0269] 310 course of individual temperature [0270] 312 course of individual heat transfer coefficient [0271] 314 diagram [0272] 316 suboptimal point [0273] 318 optimal point [0274] 320 course of coating weight per area [0275] 322 course of surface temperature [0276] 324 course of solvent volume fraction [0277] 326 course of evaporation rate [0278] 410 computer-implemented method for adjusting at least one drying process designated for producing at least one coating on at least one substrate [0279] 412 receiving step [0280] 414 employing step [0281] 416 determining step [0282] 418 providing step [0283] 420 system for adjusting at least one drying process designated for producing at least one coating on at least one substrate [0284] 422 additional communication interface