This can be done with pressure rolls having high friction coverings, with vacuum conveyer systems, or with drive belts having cogs or raised bosses to push the parts through. In order to travel in the opposite direction from the coating roller, the part must be driven in a positive manner so that it does not slip. The difficulties in reverse roll coating are in driving the part and in dealing with any coating build-up on the leading or trailing edges of the part. The result of these two effects working together can provide coatings that are very flat and smooth. Since the coating is heavier, it tends to flow out better, and the flow from the puddle at the roller to part interface tends to smooth out the coating.
It is also possible to apply a very smooth coating by using the reverse roll technique. Reverse roll coating is used to apply heavier coatings than might be possible with forward roll coating. This type of adhesive would form clumps which would clog the metering blade to roller interface. For this reason materials such as latex adhesives do not run well in machines having metering blades. This situation occurs between a metering blade and a coating roller. Some types of coatings also tend to congeal or clump if subjected to situations where there are shear forces on the liquid. In cases where the debris is abrasive, it can cause damage to the surface of the roller. This can block a portion of the coating from passing through the gap, which can cause streaks or inconsistent coating results. Clogging can occur if debris or foreign matter in the liquid gets caught in the gap between the coating roller and the metering blade. Two disadvantages are the potential for clogging and potential for roller damage. The advantages of a metering blade over other means of coating thickness control are low cost, simplicity of design, and the fact that the metering blade system does not require much space. In some cases the metering blade may be moved forward and back on its mount plate, It can also be rotated to change the gap between the metering blade and the roller. The three most common approaches to controlling the coating thickness are metering blade, metering roller, and transfer from another roll.
With most rollcoaters, there is some means of controlling the thickness of the coating on the surface of the roller before it contacts the substrate. The percentage of coating that sticks to the part (the substrate) depends on the surface characteristics of both the roller and the substrate.
The layer of coating on the surface of the roll splits – part of it stays on the roller, and part sticks to the surface of the part. When this happens, a phenomenon know as “film splitting” occurs. A roll coating machine works by transferring a layer of coating from the surface of a roller to the surface of a part. Rollcoaters can take many forms, from simple paint rollers to sophisticated coating machines with multiple rollers. Rollcoaters can be used to apply liquid adhesives, paints, oils, and coatings such as varnish or clear finish coats.
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