(cid:9) (cid:9)
`
`[54]
`[54] APPLICATION MEMBER FOR APPLYING A
`APPLICATION MEMBER FOR APPLYING A
`COATING MATERIAL TO A SUBSTRATE
`COATING MATERIAL TO A SUBSTRATE
`
`Inventors: Glen H. Bayer, Jr., Cottage Grove;
`[751
`[75] Inventors: Glen H. Bayer, Jr., Cottage Grove;
`Timothy J. O’Leary, St. Paul, both of
`Timothy J. O'Leary, St. Paul, both of
`Minn.
`Minn.
`
`Assignee: Minnesota Mining and
`[731
`[73] Assignee: Minnesota Mining and
`Manufacturing Company, St. Paul,
`Manufacturing Company, St. Paul,
`Minn.
`Minn.
`
`[211
`[21]
`[22]
`[22]
`
`[63]
`[63]
`
`Appl. No.: 601,379
`Appl. No.: 601,379
`
`Filed:
`Filed: (cid:9)
`
`Feb. 14, 1996
`Feb. 14, 1996
`
`Related U.S. Application Data
`Related U.S. Application Data
`
`Continuation of Ser. No. 393,881, Feb. 23, 1995, abandoned,
`Continuation of Ser. No. 393,881, Febv 23, 1995, abandoned,
`which is a continuation of Ser. No. 56,362, Apr. 30, 1993,
`which is a continuation of Ser. No. 56,362, Apr. 30, 1993,
`abandoned.
`abandoned.
`
`[51] Int. CI.'
` BO5C 1/12; BO5D 1/28;
`Int. Cl.6 ............................. .. B05C 1112; BOSD 1/28;
`B05D 5/00; B05D 5/10
`B05D 5/00; BOSD 5/10
`[52]
`[52] U.S. Cl. (cid:9)
` 427/207.1; 427/208.6;
`U.S. Cl. ................................... .. 427/207.1; 427/208.6;
`427/288; 427/428; 118/210; 118/212; 118/244
`427/288; 427/428; 118/210; 118/212; 118/244
`[58]
`[58] Field of Search (cid:9)
` 427/207.1, 208.4,
`Field of Search ............................ .. 427/207.1, 208.4,
`427/208.6, 288, 428; 118/210, 212, 244,
`427/208.6, 288, 428; 118/210, 212, 244,
`246, 248, 249, 258, 261, 262; 29/8953,
`246, 248, 249, 258, 261, 262; 29/895.3,
`895.31, 895.32; 101/348;
`492/30, 37, 59
`895.31, 895.32; 101/348; 492/30, 37, 59
`
`[56]
`
`References Cited
`References Cited
`
`U.S. PAlh,NT DOCUMENTS
`U.S. PATENT DOCUMENTS
`
`United States Patent [19]
`United States Patent [191
`Bayer, Jr. et al. (cid:9)
`Bayer, Jr. et al.
`
`Hlllllllllllllllllllllllllllgmllslglllliulllllllllllllllllllllllllll
`1111111111111111111111111111111101111)F1,1,1181,1111111111111111111111111111
`5,597,618
`5,597,618
`[11] Patent Number: (cid:9)
`Patent Number:
`[11]
`[45] Date of Patent: (cid:9)
`Jan. 28, 1997
`Jan. 28, 1997
`[45] Date of Patent:
`
`4,302,486 11/1981 Harbs . . . . . . .
`
`4,287,846
`9/1981 Klein (cid:9)
`
`118/262
`9/1981 Klein ..................................... .. 118/262
`4,287,846
`4,302,486 11/1981 Harbs (cid:9)
`
`427/428
`4,426,344
`1/1984 Dinter et al. (cid:9)
`
`264/171
`4,426,344
`1/1984 Dinter et a1. ................... .. 264/171
`4,430,284
`2/1984 Rasmussen (cid:9)
`
`264/171
`4,430,284 2/1984 Rasmussen ..
`264/171
`4,443,397
`4/1984 Hahn et al. (cid:9)
`
`264/171
`4,443,397
`4/1984 Hahn et a1. ..
`264/171
`4,465,015
`8/1984 Osta et al. (cid:9)
`
`118/222
`4,465,015
`8/1984 Osta et a1.
`.. 118/222
`4,569,864
`2/1986 Mclntyre
`118/262
`4,569,864
`2/1986 McIntyre (cid:9)
`
`118/262
`4,669,965
`6/1987 Murakami (cid:9)
`
`425/133.5
`4,669,965
`6/1987 Murakarni .......................... .. 425/1335
`
`. . . . . . . . . , . . . . .. 427/428
`
`(List continued on next page.)
`(List continued on next page.)
`
`FOREIGN PATENT DOCUMENTS
`FOREIGN PATENT DOCUMENTS
`
`European Pat. Off. .
`0012789
`9/1980
`0012789 9/1980 European Pat. O?“. ,
`European Pat. Off. .
`0279579
`8/1988
`0279579 8/1988 European Pat. Oil‘. .
`France (cid:9)
` 118/DIG. 15
`1401083 12/1965
`1401083 12/1965 France ......................... .. 118/DIG. 15
`2442667
`France (cid:9)
` 118/261
`6/1980
`2442667 6/1980 France ................................. .. 118/261
`Germany .
`3537433
`9/1986
`3537433 9/1986 Germany .
`61-114852
`Japan .
`6/1986
`61-114852 6/1986 Japan .
`1190325
`5/1970
`United Kingdom .
`1190325 5/1970 United Kingdom .
`United Kingdom (cid:9)
` 118/261
`1381328
`1/1975
`1/1975 United Kingdom ................. .. 118/261
`1381328
`United Kingdom .
`2078140
`1/1982
`2078140 1/1982 United Kingdom .
`
`OTHER PUBLICATIONS
`OTHER PUBLICATIONS
`
`European Search Report—-El3 94 40 00931.
`European Search Report—EP 94 40 00931.
`
`Primary Examiner—Shiive Beck
`Primary Examiner—Shrive Beck
`Assistant Examiner—Fred J. Parker
`Assistant Examiner—Fred .1. Parker
`Attorney, Agent, or Firm—Gary L. Griswold; Walter N.
`Attorney, Agent, or Firm-Gary L. Griswold; Walter N.
`Kim; William L. Huebsch
`Kirn; William L. Huebsch
`
`[57] (cid:9)
`[57] -
`
`ABSTRACT
`ABSTRACT
`
`An application member for applying a coating material, such
`An application member for applying a coating material, such
`as a pressure sensitive adhesive, to a receiving surface, such
`as a pressure sensitive adhesive, to a receiving surface, such
`as a paper substrate. The application member includes a
`as a paper substrate. The application member includes a
`cylindrical peripheral surface and a plurality of spaced,
`cylindrical peripheral surface and a plurality of spaced,
`discrete structures projecting from the peripheral surface of
`discrete structures projecting from the peripheral surface of
`the hub, whereby adhesive may be carried on and between
`the hub, whereby adhesive may be carried on and between
`the structures prior to being applied to the receiving surface.
`the structures prior to being applied to the receiving surface.
`By varying the surface velocity of the application member
`By varying the surface velocity of the application member
`relative to the velocity of the substrate, the characteristics of
`relative to the velocity of the substrate, the characteristics of
`the adhesive layer applied to the substrate may be changed.
`the adhesive layer applied to the substrate may be changed.
`Also provided is a process for making the application
`Also provided is a process for making the application
`member by retaining individual particles within substan~
`member by retaining individual particles within substan-
`tially all of a plurality of indentations in the peripheral
`tially all of a plurality of indentations in the peripheral
`surface of a hub.
`surface of a hub.
`
`24 Claims, 4 Drawing Sheets
`24 Claims, 4 Drawing Sheets
`
`1,707,400
`
`4/1929 Kerruish . . . . . . .
`
`. . . .. 492/30
`
`4/1900 Henricus (cid:9)
`647,833
`
`427/270
`4/ 1900 Henricus ............................... .. 427/270
`647,833
`4/1929 Kerruish (cid:9)
`1,707,400
`
`492/30
`2,386,731 10/1945 Wenzelberger (cid:9)
`2,386,731 10/1945 Wenzelberger
`118/262
`
`118/262
`3,496,012
`2/1970 Biorseth (cid:9)
`
`117/111
`3,496,012
`2/1970 Biorseth ................................ .. 117/111
`3,559,572
`2/1971 Hackley (cid:9)
`
`118/249
`3,559,572
`2/1971 Hackley ................................ .. 118/249
`3,650,242
`3/1972 Mahoney (cid:9)
`
`118/246
`3,650,242
`3/1972 Mahoney ....... ..
`118/246
`3,729,338
`4/1973 Lehmann et al. (cid:9)
`
`427/208.4
`3,729,338
`4/1973 Lehmann et a1. .
`427/208.4
`3,941,181
`3/1976 Stoody (cid:9)
`
`164/59.1
`3,955,260
`5/1976 Sherden (cid:9)
`
`3,955,260
`5/1976 Sherden
`118/Dig. 5
`118/Dig. 5
`4,004,774
`1/1977 Houston (cid:9)
`
`427/291
`4,004,774
`1/1977 Houston ..... ..
`427/291
`4,085,702 4/1978 Consaul et al. (cid:9)
`
`118/60
`4,085,702 4/1978 Consaul et a1.
`118/60
`4,097,711
`6/1978 Benerjee (cid:9)
`
`219/76.15
`4,097,711
`6/1978 Beneijee ........ ..
`219/7615
`4,107,815
`8/1978 Durrtesnil, Jr. (cid:9)
`
`118/258
`4,107,815
`8/1978 Dumesnil, Jr.
`118/258
`4,167,914
`9/1979 Mladota (cid:9)
`
`118/33
`4,211,741
`8/1980 Ostoich (cid:9)
`
`264/173
`4,211,741
`8/1980 Ostoich
`264/173
`
`3,941,181
`
`3/1976 Stoody . . . . . . . . .
`
`. . . . .. 164/591
`
`4,167,914
`
`9/1979 Mladota . . . . . . .
`
`. . . .. 118/33
`
`Petitioner - Owens Corning
`Ex. 1007, p. 1 of 12
`
`(cid:9)
`

`
`5,597,618
`5,597,618
`Page 2
`Page 2
`
`U.S. PAIENT DOCUMENTS
`US, PATENT DOCUMENTS
`
`425/131.1
`4,772,195
`
`9/1988 Touchet (cid:9)
`4,772,195
`9/1988 Touchet .............................. .. 425/131.1
`427/428
`
`4,871,593 10/1989 McIntyre (cid:9)
`4,871,593 10/1989 McIntyre ............................... .. 427/428
`4,882,990 11/1989 (cid:9)
`Ijichi (cid:9)
`
`101/348
`4,882,990 11/1989 Ijichi ............ ..
`101/348
`4,889,234 12/1989 (cid:9) Sorenson et al. (cid:9)
`
`206/456
`4,889,234 12/1989 Sorenson et a1.
`.. 206/456
`5,030,484
`7/1991 (cid:9) Chino et al. (cid:9)
`
`427/434.3
`5,030,484
`7/1991 Chino et a1. ....................... .. 427/4343
`
`7/1991 Sonobe et al. (cid:9)
`5,033,380
`
`29/895.32
`7/1991 Sonobe et a1. ..................... .. 29/895.32
`5,033,380
`8/1991 Wirz (cid:9)
`
`5,042,383
`492/30
`8/1991 Wirz ............................ .. 492/30
`5,042,383
`5,066,435 11/1991 Lorenz et al. (cid:9)
`
`264/40.5
`_ _ _ _ _ __ 264/405
`5,066,435 11/1991 Lorenz etal _ _ _ _ _ _ _
`5,069,934 12/1991 Chino et al. (cid:9)
`
`427/131
`5,069,934 12/1991 chino etaL
`427/131
`118/411
`5,072,688 12/1991 Chino et al. (cid:9)
`
`5,072,688 12/1991 Chino et al7
`118/411
`5,099,759
`3/1992 Sonobe et al. (cid:9)
`
`29/895.32
`5,099,759
`3/1992 Sonobe et a1.
`. 29/895.32
`5,113,760
`5/1992 Sonobe et al. (cid:9)
`
`101/348
`5,113,760
`5/1992 Sonobe et a1. ........................ _. 101/348
`
`Petitioner - Owens Corning
`Ex. 1007, p. 2 of 12
`
`

`
`U.S. Patent
`US. Patent
`
`Jan. 28, 1997
`Jan. 28, 1997 (cid:9)
`
`Sheet 1 of 4
`Sheet 1 of 4
`
`5,597,618
`5,597,618
`
`13
`13
`
`18
`
`12
`
`/
`
`Fig. 1
`Fig. 1
`PRIOR ART
`PRIOR ART
`
`14
`
`32
`
`34
`
`ig. 2
`Fig. 2
`PRIOR ART
`PRIOR ART
`
`Fig. 3
`Fig. 3
`PRIOR ART
`PRIOR ART
`
`Petitioner - Owens Corning
`Ex. 1007, p. 3 of 12
`
`

`
`U.S. Patent
`US. Patent
`
`Jan. 28, 1997
`Jan. 28, 1997
`
`Sheet 2 of 4
`Sheet 2 of 4
`
`5,597,618
`5,597,618
`
`58
`
`Fig. 4
`Fig. 4
`PRIOR ART
`PRIOR ART
`
`54
`54
`Fig. 5
`Fig. 5
`PRIOR ART
`PRIOR ART
`
`jir--100
`
`,1 02
`
`Fig. 6
`
`Petitioner - Owens Corning
`Ex. 1007, p. 4 of 12
`
`

`
`U.S. Patent (cid:9)
`US. Patent
`
`Jan. 28, 1997
`Jan. 28, 1997 (cid:9)
`
`Sheet 3 of 4
`Sheet 3 of 4 (cid:9)
`
`5,597,618
`5,597,618
`
`114
`
`Fig. 7
`
`122
`
`Fig. 8
`
`Fig. 9
`Fig. 9
`
`Petitioner - Owens Corning
`Ex. 1007, p. 5 of 12
`
`

`
`U.S. Patent (cid:9)
`U.S. Patent
`
`Jan. 28, 1997 (cid:9)
`Jan. 28, 1997
`
`Sheet 4 of 4 (cid:9)
`Sheet 4 of 4
`
`5,597,618
`5,597,618
`
`‘
`
`Fig. 1
`Fig. 10
`
`Petitioner - Owens Corning
`Ex. 1007, p. 6 of 12
`
`

`
`5,597,618
`5,597,618
`
`1
`1
`APPLICATION MEMBER FOR APPLYING A
`APPLICATION MEMBER FOR APPLYING A
`COATING MATERIAL TO A SUBSTRATE
`COATING MATERIAL TO A SUBSTRATE
`
`This is a continuation of application Ser. No. 08/393,881,
`This is a continuation of application Ser. No. 08/393,881,
`filed Feb. 23, 1995, now abandoned which was a continu- 5
`?led Feb. 23, 1995, now abandoned which was a continu
`ation of application Ser. No. 08/393,362, ?led Apr. 30, 1993,
`ation of application Ser. No. 08/393,362, filed Apr. 30, 1993,
`now abandoned.
`now abandoned.
`
`TECHNICAL FIELD
`TECHNICAL FIELD
`
`The invention relates to a method and apparatus for
`The invention relates to a method and apparatus for
`applying coating material to a receiving surface.
`applying coating material to a receiving surface.
`
`10
`10
`
`BACKGROUND OF THE INVENTION
`BACKGROUND OF THE INVENTION
`
`2
`2
`are matched, a particular application roller consistently
`are matched, a particular application roller consistently
`applies the same pattern and thickness of coating material to
`applies the same pattern and thickness of coating material to
`the substrate. To change the pattern or thickness of coating
`the substrate. To change the pattern or thickness of coating
`material that is applied to the substrate, the application roller
`material that is applied to the substrate, the application roller
`must be removed and replaced with a coating roller having
`must be removed and replaced with a coating roller having
`different surface characteristics (e.g. more or less cells,
`diiferent surface characteristics (e.g. more or less cells,
`greater or smaller spacing between adjacent cells, or deeper
`greater or smaller spacing between adjacent cells, or deeper
`or more shallow cells). The coating process must be halted
`or more shallow cells). The coating process must be halted
`while a new application roller is attached to the coating
`while a new application roller is attached to the coating
`apparatus, and roller replacement is therefore costly and
`apparatus, and roller replacement is therefore costly and
`undesirable. It would therefore be desirable to provide a
`undesirable. It would therefore be desirable to provide a
`method and apparatus for applying a coating material in
`method and apparatus for applying a coating material in
`different amounts and in varying patterns, without having to
`different amounts and in varying patterns, without having to
`replace the application roller.
`replace the application roller.
`Planographic coating is similar to gravure coating in some
`Planographic coating is similar to gravure coating in some
`regards, and includes such coating methods as ?exography,
`regards, and includes such coating methods as flexography,
`lithography, and both wet and dry o?set coating. A notable
`lithography, and both wet and dry offset coating. A notable
`difference between gravure coating and planographic coat
`difference between gravure coating and planographic coat-
`ing relates to the peripheral surface of the application roller,
`ing relates to the peripheral surface of the application roller,
`and the manner in which the coating material is carried on
`and the manner in which the coating material is carried on
`that surface. Whereas gravure coating uses an application
`that surface. Whereas gravure coating uses an application
`roller having a plurality of cells that are recessed from the
`roller having a plurality of cells that are recessed from the
`peripheral surface of the application roller, planographic
`peripheral surface of the application roller, planographic
`coating uses a pattern roller 50 having a multitude of island
`coating uses a pattern roller 50 having a multitude of island
`portions 52 that are raised above peripheral surface 54, as
`portions 52 that are raised above peripheral surface 54, as
`shown in FIGS. 4 and 5. The coating material 56 is carried
`shown in FIGS. 4 and 5. The coating material 56 is carried
`only on the outermost surface of each island portion 52, and
`only on the outermost surface of each island portion 52, and
`the pattern roller 50 contacts the application roller 55 to
`the pattern roller 50 contacts the application roller 55 to
`transfer the coating material thereto. The application roller
`transfer the coating material thereto. The application roller
`then transfers coating material 56 onto a substrate 58 in the
`then transfers coating material 56 onto a substrate 58 in the
`desired pattern.
`desired pattern.
`Although planographic coating also has certain bene?ts, it
`Although planographic coating also has certain benefits, it
`is difficult to alter the coating parameters quickly and
`is di?‘icult to alter the coating parameters quickly and
`inexpensively. To change the pattern or thickness of coating
`inexpensively. To change the pattern or thickness of coating
`material applied to the substrate, the pattern roller must
`material applied to the substrate, the pattern roller must
`typically be replaced, because the characteristics of a par-
`typically be replaced, because the characteristics of a par
`ticular pattern roller determine the pattern and thickness of
`ticular pattern roller determine the pattern and thickness of
`coating material that will be applied to the substrate.
`coating material that will be applied to the substrate.
`Replacement of the pattern roller must take place when the
`Replacement of the pattern roller must take place when the
`coating process is stopped, and is therefore undesirable for
`coating process is stopped, and is therefore undesirable for
`the same reasons as stated above with reference to gravure
`the same reasons as stated above with reference to gravure
`coating. Furthermore, if several different pattern rollers must
`coating. Furthermore, if several different pattern rollers must
`be available for each coating apparatus to provide a desired
`be available for each coating apparatus to provide a desired
`coating thickness or pattern, the investment in pattern rollers
`coating thickness or pattern, the investment in pattern rollers
`may be substantial.
`may be substantial.
`It is therefore desirable to provide a method and apparatus
`It is therefore desirable to provide a method and apparatus
`for applying coating material to a substrate, wherein the
`for applying coating material to a substrate, wherein the
`coating characteristics may be altered without replacing the
`coating characteristics may be altered without replacing the
`application roller.
`application roller.
`
`15
`
`20
`
`25
`25
`
`30
`
`35
`35
`
`40
`
`45
`
`50
`
`It is often desirable to coat a substrate with a coating
`It is often desirable to coat a substrate with a coating
`material, such as ink or an adhesive, in a desired location on
`material, such as ink or an adhesive, in a desired location on
`the substrate. For example, pressure sensitive adhesive tape
`the substrate. For example, pressure sensitive adhesive tape
`includes a web substrate coated with a layer of pressure
`includes a web substrate coated with a layer of pressure
`sensitive adhesive. Similarly, POST-IT brand repositionable
`sensitive adhesive. Similarly, POST-IT brand repositionable
`notes, available from the Minnesota Mining and Manufac-
`notes, available from the Minnesota Mining and Manufac
`turing Company of St. Paul, Minn, include a substrate
`turing Company of St. Paul, Minn., include a substrate
`having a band of pressure sensitive adhesive coated over a
`having a band of pressure sensitive adhesive coated over a
`portion of the substrate. In these and other fields, it is
`portion of the substrate. In these and other ?elds, it is
`desirable to apply the coating material to the substrate in a
`desirable to apply the coating material to the substrate in a
`controlled manner.
`controlled manner.
`One process of applying a coating material to a substrate
`One process of applying a coating material to a substrate
`is known as gravure coating, and is illustrated schematically
`is known as gravure coating, and is illustrated schematically
`in FIG. 1. The process includes a supply 12 of a substrate 10,
`in FIG. 1. The process includes a supply 12 of a substrate 10,
`an application roller 14, and a supply of coating material 18
`an application roller 14, and a supply of coating material 18
`through which the application roller is drawn. Also shown
`through which the application roller is drawn. Also shown
`are a backing roller 19 that opposes the application roller, a
`are a backing roller 19 that opposes the application roller, a
`doctor blade 21 for wiping excess coating material from the
`doctor blade 21 for wiping excess coating material from the
`application roller, and a winding system having one or more
`application roller, and a winding system having one or more
`rollers 13 to draw the substrate between the application
`rollers 13 to draw the substrate between the application
`roller and the backing roller. As shown in FIG. 2, the
`roller and the backing roller. As shown in FIG. 2, the
`application roller includes a peripheral surface 30 having a
`application roller includes a peripheral surface 30 having a
`multitude of individual cells 32 that are recessed from the
`multitude of individual cells 32 that are recessed from the
`peripheral surface of the application roller. The cells may be
`peripheral surface of the application roller. The cells may be
`arranged in any pattern, as shown in FIG. 3, wherein cells 32
`arranged in any pattern, as shown in FIG. 3, wherein cells 32
`are formed in the peripheral surface at certain locations, and
`are formed in the peripheral surface at certain locations, and
`no cells are formed in locations 34.
`no cells are formed in locations 34.
`The cells collect the coating material as the application
`The cells collect the coating material as the application
`roller passes through the supply of coating material, and thus
`roller passes through the supply of coating material, and thus
`the areas of the peripheral surface without cells (e.g. loca-
`the areas of the peripheral surface without cells (e.g. loca
`tions 34) do not collect coating material. If any residual
`tions 34) do not collect coating material. If any residual
`coating material collects on the peripheral surface of the
`coating material collects on the peripheral surface of the
`application roller, doctor blade 21 wipes that material from
`application roller, doctor blade 21 wipes that material from
`the peripheral surface prior to contact with the substrate.
`the peripheral surface prior to contact with the substrate.
`When the substrate passes the application interface
`When the substrate passes the application interface
`between the application roller and the backing roller, the
`between the application roller and the backing roller, the
`material is drawn out of each of the cells because the coating
`material is drawn out of each of the cells because the coating
`material has a greater affinity for the substrate than for the
`material has a greater a?inity for the substrate than for the
`application roller. The surface speed of the application roller
`application roller. The surface speed of the application roller
`is matched to the speed of the substrate, to enable complete
`is matched to the speed of the substrate, to enable complete
`removal of the coating material from the individual cells. If
`removal of the coating material from the individual cells. If
`the surface speed of the substrate is greater than or less than
`the surface speed of the substrate is greater than or less than
`that of the surface of the application roller, the cells of the
`that of the surface of the application roller, the cells of the
`application roller will not be entirely evacuated. Incomplete
`application roller will not be entirely evacuated. Incomplete
`evacuation of the cells is undesirable, because the predeter-
`evacuation of the cells is undesirable, because the predeter
`mined amount of coating material has not been transferred
`mined amount of coating material has not been transferred
`to the substrate.
`to the substrate.
`Gravure coating, while having its own utility, is not easily
`Gravure coating, while having its own utility, is not easily
`modified to enable a thinner or thicker layer of coating
`modi?ed to enable a thinner or thicker layer of coating
`material to be applied to the substrate. Because the cells on 65
`material to be applied to the substrate. Because the cells on
`65
`the peripheral surface have a fixed size and shape, and
`the peripheral surface have a ?xed size and shape, and
`because the speed of the application roller and the substrate
`because the speed of the application roller and the substrate
`
`55
`55
`
`60
`
`SUMMARY OF THE INVENTION
`SUMMARY OF THE INVENTION
`
`The present invention includes an application member for
`The present invention includes an application member for
`transferring a coating material from a supply of such mate-
`transferring a coating material from a supply of such mate
`rial to a receiving surface, and for applying the material to
`rial to a receiving surface, and for applying the material to
`the receiving surface. The application member includes a
`the receiving surface. The application member includes a
`hub having a central axis for rotation thereabout, and having
`hub having a central axis for rotation thereabout, and having
`a generally cylindrical peripheral surface, and a plurality of
`a generally cylindrical peripheral surface, and a plurality of
`spaced, discrete structures projecting from the peripheral
`spaced, discrete structures projecting from the peripheral
`surface of the hub. Rotation of the hub about the central axis
`surface of the hub. Rotation of the hub about the central axis
`enables the peripheral surface to pass a source of the coating
`enables the peripheral surface to pass a source of the coating
`material to receive the coating material, and to carry the
`material to receive the coating material, and to carry the
`coating material on the peripheral surface of the hub
`coating material on the peripheral surface of the hub
`between and on said projecting structures toward an appli-
`between and on said projecting structures toward an appli
`cation interface to transfer the material from the peripheral
`cation interface to transfer the material from the peripheral
`surface to the receiving surface. Also provided is an appli-
`surface to the receiving surface. Also provided is an appli
`
`Petitioner - Owens Corning
`Ex. 1007, p. 7 of 12
`
`

`
`5,597,618
`5,597,618
`
`4
`4
`FIG. 8 is a schematic representation of the application of
`FIG. 8 is a schematic representation of the application of
`a material to a substrate, when the surface velocity of the
`a material to a substrate, when the surface velocity of the
`application roller is approximately equal to the surface speed
`application roller is approximately equal to the surface speed
`of the substrate;
`of the substrate;
`FIG. 9 is a schematic representation of the application of
`FIG. 9 is a schematic representation of the application of
`material to a substrate, when the surface velocity of the
`material to a substrate, when the surface velocity of the
`application roller is less than the velocity of the substrate;
`application roller is less than the velocity of the substrate;
`and
`and
`FIG. 10 is a schematic representation of the application of
`FIG. 10 is a schematic representation of the application of
`material to a substrate, when the surface velocity of the
`material to a substrate, when the surface velocity of the
`application roller is greater than the velocity of the substrate.
`application roller is greater than the velocity of the substrate.
`
`DETAILED DESCRIPTION OF THE
`DETAILED DESCRIPTION OF THE
`INVENTION
`INVENTION
`
`15
`15
`
`20
`20
`
`25
`25
`
`3
`3
`cation system for applying a coating material to a receiving
`cation system for applying a coating material to a receiving
`surface, including the application member described above,
`surface, including the application member described above,
`and means for rotating said hub about the central axis thereof
`and means for rotating said hub about the central axis thereof
`at a predetermined angular velocity. The rotating means
`at a predetermined angular velocity. The rotating means
`enables the peripheral surface to pass a source of the coating 5
`enables the peripheral surface to pass a source of the coating
`material to receive the coating material and to carry the
`material to receive the coating material and to carry the
`coating material on the peripheral surface between and on
`coating material on the peripheral surface between and on
`said projecting structures toward an application interface
`said projecting structures toward an application interface
`between the peripheral surface and the receiving surface,
`between the peripheral surface and the receiving surface,
`and to transfer said coating material to the receiving surface. 10
`and to transfer said coating material to the receiving surface
`An increase in the angular velocity of the hub increases the
`An increase in the angular velocity of the hub increases the
`amount of coating material transferred to the receiving
`amount of coating material transferred to the receiving
`surface, and a decrease in the angular velocity of the hub
`surface, and a decrease in the angular velocity of the hub
`decreases the amount of coating material transferred to the
`decreases the amount of coating material transferred to the
`receiving surface.
`receiving surface. (cid:9)
`In another aspect of the present invention, a method is
`In another aspect of the present invention, a method is
`provided for applying a coating material to a receiving
`provided for applying a coating material to a receiving
`surface. The method includes the steps of providing a hub
`surface. The method includes the steps of providing a hub
`having a central axis of rotation, and having a generally
`having a central axis of rotation, and having a generally
`cylindrical peripheral surface including a plurality of
`cylindrical peripheral surface including a plurality of
`spaced, discrete structures projecting from the peripheral
`spaced, discrete structures projecting from the peripheral
`surface; providing a source of the coating material in suf-
`surface; providing a source of the coating material in suf
`ficient proximity to the peripheral surface to enable the
`?cient proximity to the peripheral surface to enable the
`peripheral surface to receive the coating material and to
`peripheral surface to receive the coating material and to
`carry the coating material between and on said projecting
`carry the coating material between and on said projecting
`structures; contacting a receiving surface with the peripheral
`structures; contacting a receiving surface with the peripheral
`surface of the hub at an application interface to enable the
`surface of the hub at an application interface to enable the
`peripheral surface to transfer the coating material to the
`peripheral surface to transfer the coating material to the
`receiving surface at the interface; and rotating the hub to
`receiving surface at the interface; and rotating the hub to
`receive the coating material from the material source and to
`receive the coating material from the material source and to
`transfer the material to the receiving surface at the applica
`transfer the material to the receiving surface at the applica-
`tion interface. Also provided is a substrate coated with a
`tion interface. Also provided is a substrate coated with a
`coating material according to the method described above.
`coating material according to the method described above.
`A method is also provided for making an application
`A method is also provided for making an application
`member for applying a coating material to a receiving
`member for applying a coating material to a receiving
`surface. The method includes the steps of providing a hub
`surface. The method includes the steps of providing a hub
`having a generally cylindrical peripheral surface; forming a
`having a generally cylindrical peripheral surface; forming a
`plurality of discrete indentations in the peripheral surface;
`plurality of discrete indentations in the peripheral surface;
`and retaining a particle within substantially all of the inden-
`and retaining a particle within substantially all of the inden
`tations, such that a portion of each particle projects above
`tations, such that a portion of each particle projects above
`the peripheral surface of the hub. Thus, the application
`the peripheral surface of the hub. Thus, the application
`member is adapted to carry the coating material on and
`member is adapted to carry the coating material on and
`between the particles prior to application to the receiving
`between the particles prior to application to the receiving
`surface.
`surface.
`
`The present invention relates broadly to an application
`The present invention relates broadly to an application
`member for applying a coating material to a receiving
`member for applying a coating material to a receiving
`surface. The coating material may be any suitable material,
`surface. The coating material may be any suitable material,
`including but not limited to adhesive (e.g. pressure sensitive
`including but not limited to adhesive (e. g. pressure sensitive
`adhesive) and ink. The receiving surface may be, for
`adhesive) and ink. The receiving surface may be, for
`example, a substrate, such a continuous web of paper or
`example, a substrate, such a continuous web of paper or
`polymeric material, or a belt or roller that receives the
`polymeric material, or a belt or roller that receives the
`material and transfers the material to a substrate. Thus, the
`material and transfers the material to a substrate. Thus, the
`present invention, although described primarily with refer
`present invention, although described primarily with refer-
`ence to the application of adhesive to a substrate, also has
`ence to the application of adhesive to a substrate, also has
`broad applicability to other coating operations as well.
`broad applicability to other coating operations as well.
`FIG. 6 illustrates an applicator for applying a coating
`FIG. 6 illustrates an applicator for applying a coating
`material to a receiving surface. In the illustrated embodi-
`material to a receiving surface. In the illustrated embodi
`30 ment, an applicator apparatus 100 is shown for applying an
`ment, an applicator apparatus 100 is shown for applying an
`30
`adhesive 102 to a substrate 104, such as paper