COATING DEVICE AND COATING METHOD

Abstract

A coating device for the register-accurate application of plastic material to a carrier sheet comprises a first coating roll and a downstream second coating roll, wherein each of the first and second coating rolls has at least one cavity that can be filled with plastic material by means of at least one nozzle. First and second stripping means strip the respective first and second coating rolls. The first coating roll interacts with a first mating roll and coats a first carrier sheet side and the second coating roll interacts with a second mating roll and coats a second carrier sheet side. The second mating roll comprises at least one mating cavity corresponding to the at least one first cavity. In addition, the coating device comprises at least one carrier sheet positioning device and a coated region detection device. Related methods of coating a carrier sheet are also disclosed.

Claims

1. A coating device for the register-accurate application of plastic material to a carrier sheet, comprising: a first coating roll, and a downstream second coating roll, wherein the first coating roll has at least one first cavity and can be filled with plastic material by means of at least one first nozzle, and wherein the second coating roll has at least one second cavity and can be filled with plastic material by means of at least one second nozzle, and wherein a first stripping means strips the first coating roll and a second stripping means strips the second coating roll, and wherein the first coating roll interacts with a first mating roll and coats a first carrier sheet side and the second coating roll interacts with a second mating roll and coats a second carrier sheet side, and wherein the second mating roll comprises at least one mating cavity corresponding to the at least one first cavity, and the coating device further comprising at least one carrier sheet positioning device, and at least one region detection device, which detects the position of a first coated region of plastic material coated by the at least one first cavity.

2. The coating device according to claim 1, wherein at least one inner surface of at least one of the cavities has a structure.

3. The coating device according to claim 1, wherein at least one inner surface of at least one of the cavities has a coating.

4. (canceled)

5. The coating device according to claim 1, further comprising a thickness measure with respect to a filling of the at least one first cavity and/or of the at least one second cavity.

6. The coating device according to claim 1, wherein the carrier sheet positioning device comprises at least one of a sliding means of the first and/or second coating roll, or at least one carrier sheet moving means.

7. The coating device according to claim 1, wherein the region detection device comprises at least one of a mechanical sensor, an optical sensor or a coding at the first and/or second coating roll.

8. The coating device according to claim 1, wherein the region detection device detects the position of at least one edge of the first coated region and/or of at least one edge of the carrier sheet.

9. The coating device according to claim 1, further comprising a dispenser unit for applying at least one film strip.

10. The coating device according to claim 9, wherein the at least one film strip is applied to the carrier sheet by the dispenser unit along at least one edge of the first and/or second coated region.

11. The coating device according to claim 1, further comprising at least one plasticizing unit, which is arranged upstream of the at least one first nozzle and/or of the at least one second nozzle.

12. The coating device according to claim 1, wherein the first and/or second stripping means comprises at least one of a squeegee or a squeegee roll.

13. The coating device according to claim 1, wherein the at least one first nozzle and/or the at least one second nozzle are adjustable.

14. The coating device according to claim 1, further comprising at least one cleaning unit for cleaning the carrier sheet, wherein the cleaning unit is provided and suitable for cleaning at least one side of the carrier sheet.

15. The coating device according to claim 1, further comprising at least one roughening unit for roughening the carrier sheet, wherein the roughening unit is provided and suitable for roughening at least one side of the carrier sheet.

16. The coating device according to claim 1, further comprising at least one smoothing unit for smoothing the carrier sheet, wherein the smoothing unit is provided and suitable for smoothing at least one side of the carrier sheet.

17. The coating device according to claim 1, further comprising at least one processing unit for processing the carrier sheet, wherein the processing unit is provided and suitable for processing at least one side and/or one edge of the carrier sheet.

18. The coating device according to claim 11, wherein a mixer is arranged upstream of the at least one plasticizing unit.

19. The coating device according to claim 11, wherein the at least one plasticizing unit is controlled via a throughput control.

20. The coating device according to claim 11, wherein a feed block is arranged between the at least one plasticizing unit and the at least one first nozzle and/or the at least one second nozzle.

21. The coating device according to claim 1, wherein the at least one first nozzle and/or the at least one second nozzle are each configured as a deposit unit comprising multiple nozzles, and wherein the multiple nozzles apply the plastic material to the first coating roll and/or second coating roll in succession or next to one another or so as to overlap.

22. The coating device according to claim 21, wherein the first and/or second nozzles are provided and suitable for inserting different plastic materials in the cavity.

23. The coating device according to claim 1, wherein the at least one first cavity and/or the at least one second cavity have different levels and each level is assigned at least one nozzle and at least one stripping unit.

24. A coating method for coating a carrier sheet with plastic material, comprising the steps: filling at least one first cavity of a first coating roll with plastic material by means of at least one first nozzle; stripping the at least one first cavity by a first stripping means; applying the plastic material to a first carrier sheet side in a first coated region by interaction of the first coating roll with a first mating roll; filling at least one second cavity of a second coating roll with plastic material by means of at least one second nozzle; stripping the at least one second cavity by a second stripping means; detecting the position of the first coated region of plastic material coated by the at least one first cavity by a region detection device; applying the plastic material to a second carrier sheet side by interaction of the second coating roll with a second mating roll, wherein the second mating roll is controlled such that at least one mating cavity of the second mating roll receives the first coated region during application of the plastic material to the second carrier sheet side.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] For the purpose of better understanding of the device, it will be elucidated in more detail by means of the figures below. The method will be explained in more detail in the description of the device.

[0040] The figures show in a respectively very simplified schematic representation:

[0041] FIG. 1 a grossly schematic coating device in a side view,

[0042] FIG. 2 a detailed view of a coating roll,

[0043] FIG. 3 a grossly schematic coating device in a top view.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0044] First of all, it is to be noted that, in the different embodiments described, equal parts are provided with equal reference numbers and/or equal component designations, where the disclosures contained in the entire description may be analogously transferred to equal parts with equal reference numbers and/or equal component designations. Moreover, the specifications of location, such as at the top, at the bottom, at the side, chosen in the description refer to the directly described and depicted figure, and in case of a change of position, these specifications of location are to be analogously transferred to the new position.

[0045] The term in particular shall be understood below to mean that it can be a possible, more specified embodiment or narrower specification of an object, or of a method step, but need not necessarily represent an imperative, preferred embodiment of same, or an imperative procedure.

[0046] In their present use, the terms comprising, comprises, having, includes, including, contains, containing and any variations of these shall cover a non-exclusive inclusion.

[0047] Other terms that are also used are optionally or alternatively. These are to be understood to mean that this method step or this plant component is generally present but can be used depending on the conditions of use and need not necessarily be used.

[0048] FIG. 1 shows a grossly schematic coating device 10 in a side view and/or represents a method process and/or a method flow chart of a coating method for coating a carrier sheet 11 with plastic material.

[0049] The coating device 10 is provided for the register-accurate application of plastic material to a carrier sheet 11, in particular to a first carrier sheet side 11a of the carrier sheet 11 and/or to a second carrier sheet side 11b of the carrier sheet 11. To that end, the coating device 10 comprises a first coating roll 20 and a second coating roll 30 arranged downstream of the first coating roll 20. Here, terms such as downstream, after or subsequent refer to the processing direction and/or process flow direction of the coating device 10. Here, the carrier sheet 11 is inserted in the coating device and guided through same so as to follow the processing direction. In the flow chart shown in FIG. 1, the processing direction is from right to left and is indicated by means of an arrow for better understanding.

[0050] The first coating roll 20 has at least one first cavity 21 and can be filled with a plasticized plastic material by means of at least one first nozzle 22. The second coating roll 30 has at least one second cavity 31 and can be filled with a plasticized plastic material by means of at least one second nozzle 32. A first stripping means 23 strips the first coating roll 20 and a second stripping means 33 strips the second coating roll 30.

[0051] Here, the first coating roll 20 interacts with a first mating roll 40, wherein the carrier sheet 11 is guided through between the first coating roll 20 and the first mating roll 40. Here, the first carrier sheet side 11a and/or, in the example represented, the top side of the carrier sheet 11 faces the first coating roll 20. The first carrier sheet side 11a of the carrier sheet 11 is thus coated by means of the first coating roll 20.

[0052] The second coating roll 30 interacts with a second mating roll 50, wherein the carrier sheet 11 is guided through between the second coating roll 30 and the second mating roll 50. Here, the second carrier sheet side 11b and/or, in the example represented, the bottom side of the carrier sheet 11 faces the second coating roll 30. The second carrier sheet side 11b of the carrier sheet 11 is thus coated by means of the second coating roll 30.

[0053] The second mating roll 50 comprises at least one mating cavity 51, which at least one mating cavity 51 corresponds to the at least one first cavity 21. Furthermore, the coating device 10 comprises at least one carrier sheet positioning device 60.

[0054] Here, the coating device 10 shown in FIG. 1 can be used in a coating method for coating a carrier sheet 11 with plastic material. In the method, a carrier sheet 11 is guided through a coating device 10 and coated at least partially, preferably on both sides. To that end, the method first provides a filling of at least one first cavity 21 of a first coating roll 20 with a plastic material by means of at least one first nozzle 22. To remove excess plastic material, the at least one first cavity 21 is stripped by means of a first stripping means 23.

[0055] A rotational movement of the first coating roll 20 ensures that the plastic material is applied to a first carrier sheet side 11a of the carrier sheet 11, resulting in a first coated region 29. Subsequently, at least one second cavity 31 of a subsequent, second coating roll 30 is filled with plastic material by means of at least one second nozzle 32. Also this second cavity 31 is stripped by means of a second stripping means 33. A rotational movement of the second coating roll 30 ensures that the plastic material is applied to a second carrier sheet side 11b of the carrier sheet 11, resulting in a second coated region 39. Here, a second mating roll 50, which interacts with the second coating roll 30, is controlled such that at least one mating cavity 51 of the second mating roll 50 the at least one mating cavity 51 receives the first coated region 29 during application of the plastic material to the second carrier sheet side 11b.

[0056] At least one inner surface of at least one of the cavities 21, 31, 51 can have a structure. FIG. 1 shows that, due to the structures of the cavities 21, 31, 51, the first coated region 29 and the second coated region 39 have a structure. It may also be the case that at least one inner surface of at least one of the cavities 21, 31, 51 has a coating, so that the plastic material received in the cavities 21, 31, 51 and to be released does not adhere to the cavities 21, 31, 51.

[0057] The coating device 10 can further be configured with at least one region detection device 61, which detects the position of a first coated region 29 of plastic material coated by the at least one first cavity 21.

[0058] The coating device 10 can further comprise a thickness measurenot shown in the figureswhich measures a filling of the at least one first cavity 21 and/or of the at least one second cavity 31. For example, a thickness measure can be configured as a component of the region detection device 61. Alternatively, a thickness measure can also be configured in the respective cavity 21, 31, or in close proximity to the respective cavity 21, 31.

[0059] The carrier sheet positioning device 60 can comprise at least one sliding means 62 for sliding the first and/or second coating roll 20, 30, and/or at least one carrier sheet moving means 63 for moving the carrier sheet 11.

[0060] Furthermore, the region detection device 61 can comprise a mechanical sensor, an optical sensor, and/or a coding at the first and/or at the second coating roll 20, 30. The region detection device 61 can detect the position of at least one edge of the first coated region 29 and/or of at least one edge of the carrier sheet 11.

[0061] Further, the coating device 10 can comprise a dispenser unit for applying at least one film strip, which dispenser unit is not shown in the figures because it is generally known to those working in the field. Here, the dispenser unit can be arranged at the front end of the coating device 10, i.e. before the first pair of rolls 20, 40, between the pairs of rolls 20,40 and/or 30, 50 or after the second pair of rolls 30, 50. Here, the at least one film strip can be applied to the carrier sheet 11 by the dispenser unit along at least one edge of the first and/or second coated region 29, 39.

[0062] It may also be the case that the coating device 10 comprises at least one plasticizing unit, which is arranged upstream of the at least one first nozzle 22 and/or of the at least one second nozzle 32 and is not shown in the figures because it is generally known to those working in the field. A mixer, which is also not shown in the figures, can be arranged upstream of the at least one plasticizing unit. It may also be the case that the at least one plasticizing unit is controlled via a throughput control, which is also not shown in the figures. In addition, a feed block can be arranged between the at least one plasticizing unit and the at least one first nozzle 22 and/or the at least one second nozzle 32. Also the feed block is not represented in FIG. 1 because it is sufficiently known to those working in the field.

[0063] The first and/or the second stripping means 23, 33 can comprise at least one squeegee and/or one squeegee roll. It may also be the case that the at least one first nozzle 22 and/or the at least one second nozzle 32 is adjustable.

[0064] Further, the coating device 10 can comprise at least one cleaning unit 67 for cleaning the carrier sheet 11, wherein the cleaning unit 67 is provided and suitable for cleaning at least one side 11a, 11b of the carrier sheet 11. Further, the coating device 10 can comprise at least one roughening unit 68 for roughening the carrier sheet 11, wherein the roughening unit 68 is provided and suitable for roughening at least one side 11a, 11b of the carrier sheet 11. Further, the coating device 10 can comprise at least one smoothing unit 69 for smoothing the carrier sheet 11, wherein the smoothing unit 69 is provided and suitable for smoothing at least one side 11a, 11b of the carrier sheet 11. Further, the coating device 10 can comprise at least one processing unit 70 for processing the carrier sheet 11, wherein the processing unit 70 is provided and suitable for processing at least one side 11a, 11b and/or one edge of the carrier sheet 11.

[0065] For the sake of simplicity, the cleaning unit 67, the roughening unit 68, the smoothing unit 69 and the processing unit 70 are represented in FIG. 1 as a joint unit. Yet, evidently, it may also be expedient and/or required that the units are arranged individually and/or independent of one another at the most suitable respective positions in the coating device 10.

[0066] Furthermore, it may be the case that the at least one first nozzle 22 and/or the at least one second nozzle 32 are each configured as a deposit unit comprising multiple nozzles. Here, the multiple nozzles can apply the plastic material to the first coating roll 20 and/or to the second coating roll 30 in succession or next to one another or so as to overlap.

[0067] In particular, the first 22 and/or second nozzles 32 can be provided and suitable for inserting different plastic materials in the cavity 21, 31.

[0068] FIG. 2 shows a detailed view of a coating roll 20 in a side view. What is shown here is that the at least one first cavity 21 can have different levels 21a, 21b, wherein each level 21a, 21b can be assigned at least one nozzle and at least one stripping unit. Therefore, a first level 21a of the cavity 21 can be filled with a plastic material and stripped before a second level 21b is filled with an optionally different plastic material and stripped. Evidently, it may also be the case that the second level 21b is filled first and the first level 21a subsequently. Also a simultaneous filling of the levels 21a, 21b is conceivable. It should be understood that also the second coating roll 30 and/or its cavity 31 can be configured with multiple levels.

[0069] FIG. 3 shows another and optionally independent embodiment of the coating device, wherein the same reference numbers as in the preceding FIG. 1 are used for the same parts. To avoid unnecessary repetitions, the detailed description in the preceding FIG. 1 should be noted and/or is referred to.

[0070] Specifically, FIG. 3 shows a grossly schematic representation of a coating device 10 in a top view. For better clarity, the nozzles and stripping means, for example, are not represented in FIG. 3.

[0071] Here, the first cavity 21 of the first coating roll 20 is configured in the center and/or middle of the roll. In the view represented, from above onto the coating device 10, the first mating roll 40, which is arranged beneath the first coating roll 20, is not visible. When running through the coating device 10 in processing direction (represented by an arrow), a first coated region 29 is applied to the first carrier sheet side 11a and/or to the top side of the carrier sheet 11. Here, the dimension of the region 29 corresponds to that of the first cavity 21. In the further run through the coating device 10, the carrier sheet 11 is guided through a second pair of rolls, specifically through a second mating roll 50 and through a second coating roll 30. The second mating roll 50, which acts in equal measure as the first coating roll 20 on the first carrier sheet side 11a and/or on the top side of the carrier sheet 11 represented, has a mating cavity 51 here, which corresponds to the first cavity 21, i.e. is at least approximately identical to same in size and shape. It may also be the case that the mating cavity 51 is larger than the first cavity 21. When running through the second pair of rolls, the first coated region 29 hence remains undamaged and/or uninfluenced by the mating roll 50 because same is received exactly and/or in its exact position by the mating cavity 51. By means of the second coating roll 30, which has a second cavity 31, a second coated region 39 is applied to the second carrier sheet side 11b and/or to the bottom side of the carrier sheet 11. In the exemplary embodiment represented, the second coated region 39 is configured so as to be offset to the first coated region 29 in two axes. It should be understood that the precise arrangement of the regions 29, 39 is at the discretion of the skilled person and/or in accordance with the specific requirements for the product to be made.

[0072] Furthermore, FIG. 3 shows an outline of a carrier sheet positioning device 60, which can be operatable by means of a motor. In the example represented, the carrier sheet positioning device 60 is arranged at the second pair of rolls, in particular at the second coating roll 30. Evidently, the carrier sheet positioning device 60 can also be coupled with both pairs of rolls, or it may also be the case that another carrier sheet positioning device 60 is configured, which is arranged at the first pair of rolls. The carrier sheet positioning device 60 can be configured with a sliding means 62 for sliding the second coating roll 30. In addition, the carrier sheet positioning device 60 can be configured with a carrier sheet moving means 63 for moving the carrier sheet 11. Conceivable directions of movement and/or positioning which can be executed by means of the carrier sheet positioning device 60 are indicated in FIG. 3 by means of direction arrows. FIG. 3 also shows that a region detection device 61 can be configured, which is provided for detecting the first coated region 29 on the first carrier sheet side 11a. In the example represented, the region detection device 61 is coupled with the drive of the carrier sheet positioning device 60 and/or supplied with energy by same. The region detection device 61 can be configured with a camera and with a limit switch, for example.

[0073] The exemplary embodiments show possible embodiment variants, wherein it should be noted in this respect that the disclosure is not restricted to these particular illustrated embodiment variants of it, but that rather also various combinations of the individual embodiment variants are possible and that this possibility of variation owing to the teaching for technical action provided by the present disclosure lies within the ability of the person skilled in the art in this technical field.

[0074] The scope of protection is determined by the claims. However, the description and the drawings are to be adduced for construing the claims. Individual features or feature combinations from the different exemplary embodiments shown and described may represent independent inventive solutions. The object underlying the independent inventive solutions may be gathered from the description.

[0075] Any and all specifications of value ranges in the description at issue are to be understood to comprise any and all sub-ranges of same, for example the specification 1 to 10 is to be understood to mean that any and all sub-ranges starting from the lower limit 1 and from the upper limit 10 are comprised therein, i.e. any and all sub-ranges start at a lower limit of 1 or larger and end at an upper limit of 10 or less, e.g. 1 to 1.7, or 3.2 to 8.1, or 5.5 to 10.

[0076] Finally, as a matter of form, it should be noted that for ease of understanding of the structure, elements are partially not depicted to scale and/or are enlarged and/or are reduced in size.