Method and apparatus for forming articles with non-uniformly patterned coatings

Abstract

A process for applying a coating material onto a substrate as a non-uniform patterned layer of coating material, the method including providing a first distribution manifold having a cavity and a first multiplicity of dispensing outlets in fluid communication with the cavity, providing a second distribution manifold having a cavity and a second multiplicity of dispensing outlets in fluid communication with the cavity, creating relative motion between a substrate and the dispensing outlets in a first direction, dispensing a first coating material from the first dispensing outlets while maintaining the relative motion and simultaneously translating the plurality of dispensing outlets in a second direction non-parallel to the first direction, and dispensing a second coating material from the second dispensing outlets while maintaining the relative motion and simultaneously translating the plurality of dispensing outlets in a second direction non-parallel to the first direction. Useful non-uniformly patterned coated articles can be prepared using the process.

1 . A method of applying a coating material to a substrate, comprising:
 providing a first distribution manifold having a cavity and a first plurality of dispensing outlets in fluid communication with the cavity;   providing a second distribution manifold having a cavity and a second plurality of dispensing outlets in fluid communication with the cavity; and   creating relative motion between a substrate and the dispensing outlets in a first direction;   dispensing a first coating material from the first dispensing outlets onto the substrate while maintaining the relative motion, and simultaneously translating the plurality of dispensing outlets in a second direction non-parallel to the first direction; and   dispensing a second coating material from the second dispensing outlets onto the substrate while maintaining the relative motion, and simultaneously translating the plurality of dispensing outlets in a second direction non-parallel to the first direction.   
     
     
         2 . The method according to  claim 1  wherein the second plurality of dispensing outlets is interleaved with the first plurality of dispensing outlets. 
     
     
         3 . The method according to  claim 1  or  2  wherein the first dispensing outlets are translated in a third direction non-parallel to the first direction and non-parallel to the second direction while dispensing coating material from the first dispensing outlets. 
     
     
         4 . The method according to  claim 3  wherein the second dispensing outlets are translated in a third direction non-parallel to the first direction and non-parallel to the second direction while dispensing coating material from the second dispensing outlets. 
     
     
         5 . The method according to  claim 3  or  4  wherein the second and third directions are substantially orthogonal to each other. 
     
     
         6 . The method according to any preceding claim wherein the first direction is a machine direction, and the second direction is a cross direction. 
     
     
         7 . The method according to  claim 6 , wherein the third direction is substantially orthogonal to a major surface of the substrate. 
     
     
         8 . A method of applying a coating material to a substrate, comprising:
 providing a first distribution manifold having a cavity and a first plurality of dispensing outlets in fluid communication with the cavity;   creating relative motion between a substrate and the dispensing outlets in a first direction;   dispensing a first coating material from the first dispensing outlets onto the substrate while maintaining the relative motion and simultaneously translating the plurality of dispensing outlets in a second direction non-parallel to the first direction, and translating the plurality of dispensing outlets in a third direction non-parallel to the first and second directions.   
     
     
         9 . The method according to any one of  claims 3 - 8  wherein the substrate has a non-uniform surface and wherein the translation in the third direction keeps the first dispensing outlets at a substantially constant height above the non-uniform surface as the substrate moves past the first dispensing outlets. 
     
     
         10 . The method according to any one of  claims 3 - 9  wherein the translation in the second and third directions causes the first coating material to be dispensed onto the substrate in the form of a plurality of ellipses, arcs, polygons, Lissajous figures, or a combination thereof. 
     
     
         11 . The method according to  claim 10  wherein the plurality of ellipses are a plurality of circles. 
     
     
         12 . The method according to  claim 10  wherein the polygons have between 3 and 12 sides. 
     
     
         13 . The method according to any one of the preceding claims wherein the distribution manifold may be separated into a manifold chamber containing the cavity, and a removable cartridge having the plurality of needle tubes. 
     
     
         14 . The method according to any one of the preceding claims wherein at least one of the first plurality of dispensing outlets or the second plurality of dispensing outlets comprises a plurality of hollow needle tubes. 
     
     
         15 . The method according to  claim 14  wherein the hollow needle tubes are flexible. 
     
     
         16 . The method according to  claim 15  wherein the flexible hollow needle tubes comprise metal, thermoplastic polymer, thermoset polymer, fused silica, or a combination thereof. 
     
     
         17 . The method according to any one of the preceding claims wherein the coating material applied to the substrate forms a single layer pattern. 
     
     
         18 . The method according to any one of the preceding claims wherein the coating material applied to the substrate forms a dual layer pattern. 
     
     
         19 . The method according to any one of  claims 1 - 7  wherein the first and second coating materials are different materials. 
     
     
         20 . A coated article prepared according to the method of any one of the preceding claims wherein the coated article is selected from an air barrier membrane, an adhesive tape, a paint masking film, or a drug delivery patch.