Web processing method and apparatus

• US 20030188965A1
• Filed: 04/05/2002
• Published: 10/09/2003
• Est. Priority Date: 04/05/2002
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Ehnes, Dale L., Shreve, Gary A., Dobbs, James N., Carlson, Daniel H., King, Gregory F., Huizinga, John S., Erickson, Luther E.
• Granted Patent: US 6,991,717 B2
• Time in Patent Office: Days
• US Class Current: 204/198
• CPC Class Codes: B65H 23/24 by fluid action, e.g. to retard the running web
• CPC Class Codes: B65H 23/32 Arrangements for turning or reversing webs
• CPC Class Codes: C25D 7/0628 In vertical cells

Abstract

The present invention relates to a web handling apparatus and process ideally suited for applications involving wet chemistry. The invention involves the horizontal processing of webs in processing containers. The web is redirected into the processing container by inserting a cassette across the web and into the processing container. The cassette includes at least one functional fluid element that facilitates processing of the web. The web handling practices of the invention improve the quality of the processed web. The invention is preferably used in electrodeposition processes.

Claims

1. An apparatus comprising,

(a) a substantially horizontal web path for directing a web,

(b) at least one processing container, and

(c) at least one cassette having at least one functional fluid element, wherein the insertion of said at least one cassette across said web path redirects said web into said processing container creating at least one festoon.

2. An apparatus according to claim 1, wherein said apparatus is utilized for electroless plating, electrodeposition, delaminating, stripping, swelling, developing, saturating, washing, cleaning, rinsing, etching, chemical milling, coating, solvent deposition, fuming, sparging or combinations thereof.

3. An apparatus according to claim 1, further comprising a web handling mechanism.

4. An apparatus according to claim 3, wherein said web handling mechanism includes one or more of a web driving device, a web guiding device, an electrical contact device, a tension sensing device or combinations thereof.

5. An apparatus according to claim 3, further comprising an offset pivot guide having a driven electrical contact roller.

6. An apparatus according to claim 1, wherein at least one functional fluid element includes fluid bearings, sparging jets, nozzles, fluid foils, pressure pads, suction elements, fluid delivery openings or combinations thereof.

7. An apparatus according to claim 1, wherein at least one functional fluid element and pressure from fluid flow are used to control web shape and position.

8. An apparatus according to claim 1, wherein two or more functional fluid elements are placed on opposing sides of said web.

9. An apparatus according to claim 1, wherein said cassette, upon insertion into said processing container, is connected to a fluid delivery system.

10. An apparatus according to claim 1, wherein said web is tensioned at less than 1000 grams total.

11. An apparatus according to claim 1, wherein said web exhibits a lateral displacement of less than 0.2 cm within said processing container.

12. An apparatus according to claim 1, wherein said functional fluid element prevents the contact of said web with rigid structural components of either said cassette or said processing container.

13. An apparatus according to claim 1, wherein residence time of said web in said processing container is adjusted by varying cassette length, varying cassette insertion distance, using multiple cassettes, varying fluid level height in the container or combinations thereof.

14. An apparatus according to claim 1, wherein said apparatus includes two or more processing containers, and at least one cassette having a functional fluid element in each of said processing containers.

15. An apparatus according to claim 1, wherein one cassette includes a fluid bearing as a web redirecting element on said cassette.

16. An apparatus according to claim 1, wherein said web is a delicate web material or a web containing delicate cantilevered structures.

17. An apparatus according to claim 16, wherein the applied stress to the web is maintained below one tenth the elastic yield stress for the delicate web.

18. An apparatus comprising,

(a) a substantially horizontal web path for directing a web, at least a portion of said web suitable for receiving an electrodeposited coating,

(b) an electrical contact device for applying a charge to said web,

(c) at least one processing container containing an electrodeposition solution, and

(d) at least one cassette having at least one functional fluid element, wherein the insertion of said at least one cassette across said web path redirects the said web into said processing container creating at least one festoon, wherein an application of a charge to said web results in an electrodeposited coating on said web.

19. An apparatus according to claim 18, wherein said electrodeposited coating has a standard deviation of coating thickness of about 4% or less.

20. An apparatus according to claim 18, further comprising a web handling mechanism.

21. An apparatus according to claim 20, wherein said web handling mechanism includes one or more of a web driving device, a web guiding device, an electrical contact device, a tension sensing device or combinations thereof.

22. An apparatus according to claim 20, further comprising an offset pivot guide having a driven electrical contact roller.

23. An apparatus according to claim 18, wherein at least one functional fluid element includes fluid bearings, sparging jets, nozzles, fluid foils, pressure pads, suction elements, fluid delivery openings or combinations thereof.

24. An apparatus according to claim 18, wherein at least one functional fluid element and pressure from fluid flow are used to control web shape and position.

25. An apparatus according to claim 18, wherein two or more functional fluid elements are placed on opposing sides of said web.

26. An apparatus according to claim 18, wherein said cassette, upon insertion into said processing container, is connected to a fluid delivery system.

27. An apparatus according to claim 18, wherein said web is tensioned at less than 1000 grams total.

28. An apparatus according to claim 18, wherein said web exhibits a lateral displacement of less than 0.2 cm within said processing container.

29. An apparatus according to claim 18, wherein said functional fluid element prevents the contact of said web with rigid structural components of either said cassette or said processing container.

30. An apparatus according to claim 18, wherein residence time of said web in said processing container is adjusted by varying cassette length, varying cassette insertion distance, using multiple cassettes, varying fluid level height in the container or combinations thereof.

31. An apparatus according to claim 18, wherein said apparatus includes two or more processing containers, and at least one cassette having a functional fluid element in each of said processing containers.

32. An apparatus according to claim 18, wherein one cassette includes a fluid bearing as a web redirecting element on said cassette.

33. An apparatus according to claim 18, wherein said web is a delicate web material or a web containing delicate cantilevered structures.

34. An apparatus according to claim 33, wherein the applied stress to the web is maintained below the elastic yield stress for the delicate web.

35. An apparatus according to claim 18, wherein said at least one cassette includes either an anode or cathode and said web functions as an opposite potential.

36. An apparatus according to claim 35, wherein said at least one cassette includes at least one mask for selective deposition of said electrodeposited coating on said web.

37. An apparatus according to claim 36, wherein an anode is attached to said at least one mask.

52. A web having an electrodeposited coating produced by the apparatus of claim 18.

53. A web according to claim 52, wherein the electrodeposited coating has a standard deviation of coating thickness of about 4% or less.

38. A method of processing a web, comprising inserting at least one cassette having at least one functional fluid element across a substantially horizontal web to introduce said web into a processing container thereby forming a festoon.

39. A method of processing a web comprising,

(a) providing a substantially horizontal web path or directing a web,

(b) providing a processing container,

(c) inserting at least one cassette having at least one functional fluid element across said web path thereby redirecting said web into said processing container to create as least one festoon.

40. A method according to claim 39, wherein said processing container includes an electrodeposition solution and said method further comprises applying a charge to said web to produce an electrodeposited coating on said web.

41. A method according to claim 40, wherein said cassette includes either an anode or cathode and said web functions as an opposite potential.

42. A method according to claim 40, wherein the electrodeposited coating has a standard deviation of coating thickness of about 4% or less.

43. A method according to claim 39, wherein said method is utilized for electroless plating, electrodeposition, delaminating, stripping, swelling, developing, saturating, washing, cleaning, rinsing, etching, chemical milling, coating, solvent deposition, fuming, sparging or combinations thereof.

44. A method according to claim 39, further comprising connecting said cassette to a fluid delivery system.

45. A method according to claim 39, wherein said web is tensioned at less than 1000 grams total.

46. A method according to claim 39, wherein said web exhibits a lateral displacement of less than 0.2 cm within said processing container.

47. A method according to claim 39, wherein residence time of said web in said processing container is adjusted by varying cassette length, varying cassette insertion distance, using multiple cassettes, varying fluid level height in the container or combinations thereof.

48. A method according to claim 39, wherein said method includes two or more processing containers, and at least one cassette having a functional fluid element in each of said processing containers.

49. A method according to claim 39, wherein one cassette includes a fluid bearing as a web redirecting element on said cassette.

50. A method according to claim 39, wherein said web is a delicate web material or a web containing delicate cantilevered structures.

51. A method according to claim 50, wherein the applied stress to the web is maintained below one tenth the elastic yield stress for the delicate web.

54. A web having an electrodeposited coating produced by the method of claim 39.