Fountain coater

Abstract: A fountain coater includes a backing roll (2) which is rotatably mounted, a fountain (5) having a slit (9) therein which is positioned adjacent the periphery of the backing roll (2) and is adapted to supply a coating colour to the surface of a web (3) in engagement with the periphery of the backing roll and a metering element (7) situated adjacent the periphery of the backing roll at a position downstream of the fountain in the direction of rotation of the backing roll for removing excess coating colour from the web. The fountain (5) is pivotally mounted and connected to an angular adjustment mechanism (29) whereby its angle of inclination with respect to the backing roll is adjustable. The fountain (5) is mounted to pivot about an axis (B) which is substantially coincident with its tip whereby when the angle of the fountain is adjusted the size of the gap between its tip and the web does not alter.

Description: The present invention relates to a fountain coater for applying a coating colour on a web and is concerned with that type of such coater which includes a backing roll which is rotatably mounted, a fountain having a slit therein which is positioned adjacent the periphery of the backing roll and is adapted to supply a coating colour to the surface of a web in engagement with the periphery of the backing roll and a metering element situated adjacent the periphery of the backing roll at a position downstream of the fountain in the direction of rotation of the backing roll for removing excess coating colour from the web, the fountain being pivotally mounted and connected to an angular adjustment mechanism whereby its angle of inclination with respect to the backing roll is adjustable. Figure 1 is a schematic side elevation of a known fountain coater of this type which includes a main body or frame 1 and a backing roll 2 supported by the frame 1 to be rotatable about an axis O. The roll 2 has an outer periphery on which elastic material (not shown) such as rubber, is carried. A web 3 to be coated engages the roll 2 to be moved thereby. A fountain 5 is mounted on a stationary frame 10 fixed to the frame 1 below the roll 2 so as to be pivotable about an axis F. The fountain 5 defines a slit 9 which extends parallel to the axis O and through which a coating colour 4 is applied to the web 3, whilst it is in engagement with the roll 2, from a header 27. The frame 1 pivotably supports a drive 11 for pivoting the fountain 5, such as an actuating cylinder which receives a piston rod 12 connected at its free end to a bracket 50 which in turn is connected to the fountain 5. A metering element 7, such as a doctor blade or rod, mounted in a holder 8, is installed downstream of the fountain 5 in the direction of movement of the web 3 so as to remove excess coating colour 4 and form a uniform colour layer 6 on the web 3. In use, the drive 11 is firstly energised to swing the fountain 5 around the axis F to set the angle of application of the coating colour 4, i.e. the angle between the web 3 and the direction of movement the colour 4 at the point at which it contacts the web. This angle, which is referred to as the fountain angle, is to be determined in accordance with the conditions, such as the material of the web 3, the type of the coating colour 4 and the feed speed V of the web 3, whereby all the coating colour 4 is applied uniformly to the web 3. Such a known fountain coater, which adjusts the fountain angle by swinging the fountain 5 around the axis F, is disadvantageous in that the gap between the tip of the fountain 5 and the surface of the web 3 is not maintained constant when the fountain angle is changed. It is thus the object of the present invention to provide a fountain coater in which the fountain angle may be adjusted without changing the gap between the tip of the fountain and the surface of the web. According to the present invention, a fountain coater of the type referred to above is characterised in that the fountain is mounted to pivot about an axis which is substantially coincident with its tip or free end. Thus due to the fact that the fountain is angularly displaceable about the tip of the fountain, the angle of the fountain with respect to the surface of the backing roller and thus of the web in engagement with it can be adjusted without substantially altering the size of the gap between the tip of the fountain and the surface of the web. In one embodiment the slit of the fountain is defined by two lips, that lip which is on the downstream side in the direction of rotation of the roll being longer than the other lip, the tip of the downstream lip lying substantially on the pivotal axis of the fountain. The slit may be linear upstream of its mouth or open end or alternatively it may be curved so that the angle subtended between the issuing stream of the coating colour and the surface of the web is greater than that subtended by the longitudinal direction of the fountain to the surface of the web. It is preferred that the fountain is carried by a bracket having a portion which extends to a point adjacent the periphery of the backing roll and that the angular adjusting mechanism comprises an angular adjusting bracket mounted on the said portion so as to be pivotable about an axis parallel to the pivotal axis of the backing roll, the fountain being supported by the angular adjusting bracket with the tip of the fountain lying substantially on the pivotal axis of the angular adjusting bracket and that there is an actuator mounted between the bracket and the angular adjusting bracket arranged to pivot the angular adjusting bracket about the axis. It is further preferred that the bracket constitutes a gap adjusting bracket which is mounted so as to be pivotable about an axis parallel to the axis of rotation of the backing roll and that an actuator is provided to pivot the gap adjusting bracket about the axis whereby the gap between the fountain and the backing roll may be adjusted. The angular adjusting mechanism may be carried by a dwell time adjusting mechanism which is pivotable about the axis of the backing roll whereby the distance between the fountain and the metering element may be adjusted. This enables the time which any excess coating colour applied by the fountain remains on the surface of the web before being removed by the metering element, which may be in the form of a doctor blade or the like, to be adjusted. If the angular adjusting mechanism and also the components which constitute the gap adjusting mechanism are installed on the dwell time adjusting mechanism, both the size of the gap between the tip of the fountain and the surface of the web and also the angle of the fountain to the surface of the web can be maintained constant when the dwell time is altered. Further features and details of the present invention will be apparent from the following description of certain preferred embodiments which is given by way of example with reference to Figures 2 to 8 of the accompanying schematic drawings, in which:- Figure 2 is a side view of a first embodiment of the present invention; Figure 3 is a view in the direction of the arrows III-III in Figure 2; Figure 4(A) is a scrap enlarged side view of certain of the components of the first embodiment; Figure 4(B) is a view similar to Figure 4(A) showing a modified construction of the fountain shown therein; Figures 5(A) and 5(B) are side views of a second embodiment of the present invention with the fountain in two different orientations; Figure 6 is a front view of the support for a dwell time adjusting mechanism installed on the drive side of the backing roll in the second embodiment; Figure 7 is an enlarged sectional view of the portion VII in Figure 6; and Figure 8 is a view in the direction of the arrows VIII-VIII in Figure 7. The same reference numerals are used as in Figure 1 to designate similar components. Referring firstly to Figures 2 to 4, at each end of the backing roll 2 the main frame 1 pivotably supports a gap adjusting bracket 16 by means of a pin 51 extending parallel to the axis of the backing roll 2. The frame 1 pivotally supports a drive 18, such as a cylinder which has an actuating rod 19 pivotally connected to a drive arm 16a of the bracket 16. The frame 1 has a support stand 52 which projects horizontally from it and on which a positioning jack 53 is mounted. The jack 53 has a rod 54 which engages the underside of a base arm 16c of the bracket 16. The above components constitute a gap adjusting mechanism 29 in which interlocked extension and contraction movements of the drive 18 and jack 53 result in swinging of the gap adjusting bracket 16 about the axis G of the pin 51. Each bracket 16 includes an operating arm 16b at the tip of which a fountain angle adjusting bracket 20 is pivotally mounted by means of a pin 21 which extends parallel to the pin 51. The bracket 16 pivotally supports a drive or actuator 26, which has a hydraulic positioning cylinder of the type having a high positional accuracy and a locking mechanism, by means of a pin 22 and the free end of the movable portion of the actuator 26 is in turn pivotally connected to a drive arm 20a of the bracket 20 so that extension and contraction of the drive 26 swings the bracket 20 about the axis B of the pin 21. A fountain 5 is mounted on the brackets 20 and extends beneath the roll 2 supported at its two ends such that its tip is substantially on the axis B. The above components constitute a fountain angle adjusting mechanism 30 and this together with the gap adjusting mechanism 29 constitute an application adjusting mechanism 31. The mode of operation of the first embodiment is as follows:- When the rod 19 of the drive 18 and the jack 53 are extended or retracted the gap adjusting brackets 16 and the fountain angle adjusting brackets 20 are both swung around the axis G of the pin 51 and the distance between the axes O and B is varied. The gap t between the tip of the fountain 5 and the surface of the web 3 contacting the surface of the roll 2 (see Figure 4(A) or 4(B)) can thus be set to a desired value by actuation of the drive 18 and the jack 53. When the drive 26 is extended or retracted under the conditions shown in Figure 2, the fountain angle adjusting bracket 20 is swung around the axis B relative to the gap adjusting bracket 16. As a result, the fountain angle Θ defined by the web 3 and the coating colour 4 at the point P at which they impinge against one another (see Figure 4(A) or 4(B)) can be set without changing the gap t between the tip of the fountain and the surface of the web 3, which had been set to the desired value as described above. Thus whilst maintaining the gap t between the tip of the fountain 5 and the surface of the web 3 at the desired value, the fountain angle can be adjusted to the desired value determined by the operational parameters, such as the material of the web 3, the type of the coating colour 4, the feed speed V of the web 3, etc. Thus, the coating colour 4 can be effectively applied to the web 3 uniformly and without splashing of the coating colour 4. If the drive 18 is a hydraulic cylinder with a locking mechanism having a sufficiently high positional accuracy, the positioning jack 53 may be omitted. Figures 5(A) and 5(B) show the second embodiment of the present invention in which the so-called dwell time can be changed as desired. The dwell time is the time period between the time at which the coating colour 4is applied to the web 3 by the fountain 5 and the time at which any excess coating colour is removed by the metering element 7. A dwell time adjusting bracket 13 is mounted at each end of the frame 1. The brackets 13 support the backing roll 2 for rotation about the axis O. A drive or actuator 14, such as a hydraulic positioning cylinder having a locking mechanism and a high positional accuracy, is pivotally mounted on the frame 1 with the actuating rod 15 of the drive 14 being pivotally connected at its free end to the end of each bracket 13. These components constitute a dwell time adjusting mechanism 28 constructed so that extension and retraction of the drives 14 swings the brackets 13 around the axis O. Each dwell time adjusting bracket 13 has a support arm 13a which is positioned adjacent to the outer periphery of the roll 2 and on which a respective gap adjusting bracket 16 is pivotally mounted by means of a pin 17 which extends parallel to the axis of the roll 2. A drive or actuator 18, such as cylinder, is mounted on the bracket 13 and has a rod 19 which is pivotally connected at its free end to the drive arm 16a of the gap adjusting bracket 16. Thus, a gap adjusting mechanism 29 is provided whereby extension and retraction of the drive 18 swings the gap adjusting brackets 16 about the axis A of the pins 17. The gap adjusting bracket 16 has an operating arm 16b which extends to the outer periphery of the backing roll 2 and to the end of which a fountain angle adjusting bracket 20 is pivotally connected by means of a pin 21 extending parallel to the pin 17. The bracket 16 has a base arm 16c to which a threaded shaft 23 is rotatably connected at its end by a pin 22, which can rotate with respect to the base arm 16c about an axis C. The screw shaft 23 is further rotatably received at an intermediate portion in a pin 24 in the fountain angle adjusting bracket 20. The pin 24 can rotate with respect to the bracket 20 about an axis D. The threaded shaft 23 is thus rotatably and unremovably connected to the base arm 16c and is rotatably received in the pin 24, which is rotatably carried on the drive arm 20a, and is in threaded engagement with a nut 25, which is fixed to the drive arm 20a, thus providing a screw jack type drive 26. If the shaft 23 is rotated about its axis E, the gap between the base arm 16c and the drive arm 20a changes and the angle of inclination of the brackets 20 and thus of the fountain 5 thus changes also. The fountain 5 is mounted on the fountain angle adjusting brackets 20 such that its tip lies approximately on the axis B of the pins 21. The fountain angle adjusting mechanism 30 and the gap adjusting mechanism 29 constitute the application adjusting mechanism 31 which is carried by the dwell time adjusting mechanism 28. The mode of operation of the second embodiment is as follows:- When the rods 19 of the drives 18 are extended or retracted, the gap adjusting brackets 16 and the fountain angle adjusting brackets 20 are swung together about the axis A of the pins 17 and the distance between the axes O and B is changed. The gap t between the tip of the fountain 5 and the surface of the web 3 (see Figure 4(A) or Figure 4(B)) can thus be set to a desired value by actuation of the drives 18. When the drives 26 are actuated by rotating the threaded shafts 23 by a motor or the like (not shown) in the position shown in Figure 5(A), the fountain angle adjusting brackets 20 are swung around the axis B of the pins 21 relative to the gap adjusting brackets 16, e.g. to the position shown in Figure 5(B). As a result, the fountain angle Θ (see Figure 4(A) or 4(B)) can be set to a desired value without changing the preset gap t. Furthermore, when the rods 15 of the drives 14 are extended or retracted when the gap t and the fountain angle Θ have been set to their desired values, the dwell time adjusting brackets 13, the gap adjusting brackets 16 and the fountain angle adjusting brackets 20 are all swung as a unit about the axis O of the roll 2. The values of t and Θ remain constant but the fountain 5 moves closer to or away from the metering element 7. Thus, the dwell time can be arbitrarily set while maintaining the gap t and the fountain angle Θ constant. In the above two embodiments, the discharge slit 9 of the fountain 5 may be defined by a pair of lips 5a and 5b of the fountain 5 such that, as shown in Figure 4(A) or 4(B), the downstream lip 5a in the direction R of rotation of the roll 2 is longer than the upstream lip 5b and it is the tip of the downstream lip 5a which is substantially on the swing axis B. This contributes to the stability and uniformity of application of the coating colour 4. The modification shown in Figure 4(B) in which the downstream lip 5a is concave to increase the fountain angle Θ is effective to prevent interference between the fountain 5 and the metering element 7. The application of the coating colour 4 to the web 3 can thus be easily controlled. In a fountain coater, the backing roll 2 must generally be replaced once every one to two months. In order to minimise the shutdown time, the replacement of the roll 2 should be effected quickly and simply. In the second embodiment of the present invention, the pivotal axis of the dwell time adjusting brackets 13 is on the axis O of the backing roll 2. There is thus no problem with the operating side of the roll 2 whereas at the drive side of the roll, because of the fact that the dwell time adjusting bracket 13 is suspended from and fixed to a cylindrical member concentrically surrounding the outer periphery of the drive journal of the backing roll 2, the drive journal will disadvantageously interfere with the cylindrical member when the roll 2 is removed for replacement. The cylindrical member must thus, worryingly, be removed temporarily. Figures 6 to 8 show an example of a fountain coater in which the fountain 5 is pivotable about the axis O of the backing roll 2 but in which the above problem is overcome and the backing roll 2 can be replaced quickly and easily. As shown in Figure 6, the backing roll 2 is supported on the main frames 1 installed on the drive and operating sides by bearings 32. On the drive side of the roll 2, a drive journal 33 connected to a motor or the like extends on the axis O of the roll 2. The dwell time adjusting brackets 13 on the drive and operating sides are pivotally suspended from support shafts 40A and 40B mounted on the extension of the axis of the backing roll 2, respectively. The support shaft 40B on the operating side comprises a shaft member 41 fixed on the frame 1, the associated dwell time adjusting bracket 13 being fitted over the outer periphery of the member 41 with the interposition of a bearing or the like. The support shaft 40A on the drive side is constructed as follows: As shown in Figures 7 and 8, bushes 35 and a bush-supporting frame 36, which together define an annular space 34 around the drive journal or shaft 33 of the backing roll 2, are respectively split into upper and lower bush portions 35a and 35b and upper and lower support frame portions 36a and 36b. The lower support frame portion 36b is fixed to the frame 1 on the drive side of the roll 2 (see Figure 6) so that the upper support frame portion 36a can be opened or closed in relation to the lower support frame portion 36b. The bush portions 35a and 35b together receive a slide member 37 of substantially U-shaped cross-section from which the dwell time adjusting bracket 13 of the dwell time adjusting mechanism 28 on the drive side of the backing roll 2 is suspended. The upper and lower bush portions 35a and 35b are fixed to the upper and lower support frame portions 36a and 36b, respectively, and the upper support frame portion 36a is pivotally mounted on a pin 38 (see Figure 8) with respect to the lower support frame 36b and may be secured by a swing bolt 39. With the arrangement described above in which the fountain 5 is pivotable about the axis O of the roll 2, the fountain 5 can be moved closer to or away from the metering element 7 for changing the dwell time (see Figure 5) while maintaining a constant gap and a constant fountain angle and the application of the coating colour 4 to the web 3 can thus be easily controlled. During replacement of the backing roll 2, the bolt 39 is loosened and the upper support frame portion 36a and the upper bush portion 35a are opened in relation to the lower support frame portion 36b and the lower bush portion 35b as shown by the chaindotted line in Figure 8 so that the drive journal 33 can be pulled upward together with the backing roll 2 and the bearings 32 by a crane or the like for replacement of the roll 2 without removing the slide member 37 because the slide member 37 has a substantially U-shaped cross-section and is open upwardly. The backing roll 2 can thus be replaced rapidly and easily and the shutdown time can be reduced.

Claims: A fountain coater including a backing roll (2) which is rotatably mounted, a fountain (5) having a slit (9) therein which is positioned adjacent the periphery of the backing roll and is adapted to supply a coating colour (4) to the surface of a web (3) in engagement with the periphery of the backing roll and a metering element (7) situated adjacent the periphery of the backing roll at a position downstream of the fountain in the direction of rotation (R) of the backing roll for removing excess coating colour from the web, the fountain being pivotally mounted and connected to an angular adjustment mechanism (30) whereby its angle of inclination Θ with respect to the backing roll is adjustable, characterised in that the fountain (5) is mounted to pivot about an axis (B) which is substantially coincident with its tip. A fountain coater as claimed in Claim 1, characterised in that the slit (9) of the fountain (5) is defined by two lips (5a, 5b), that lip (5a) which is on the downstream side in the direction of rotation of the roll (2) being longer than the other lip (5b), the tip of the downstream lip lying substantially on the pivotal axis (B) of the fountain (5). A fountain coater as claimed in Claim 1 or 2, characterised in that the fountain (5) is carried by a bracket (16) having a portion (16b) which extends to a point adjacent the periphery of the backing roll (2) and that the angular adjusting mechanism (30) comprises an angular adjusting bracket (20) mounted on the said portion (16B) so as to be pivotable about an axis (B) parallel to the pivotal axis (O) of the backing roll, the fountain (5) being supported by the angular adjusting bracket (20) with the tip of the fountain lying substantially on the pivotal axis (B) of the angular adjusting bracket (20) and that there is an actuator (26) mounted between the bracket (16) and the angular adjusting bracket (20) arranged to pivot the angular adjusting bracket (20) about the axis (B). A fountain coater as claimed in Claim 3 characterised in that the bracket (16) constitutes a gap adjusting bracket which is mounted so as to be pivotable about an axis (G) parallel to the axis (O) of rotation of the backing roll and that an actuator (18, 53) is provided to pivot the gap adjusting bracket (16) about the axis (G) whereby the gap (t) between the fountain (5) and the backing roll (2) may be adjusted. A fountain coater as claimed in any one of the preceding claims characterised in that the angular adjusting mechanism (30) is carried by a dwell time adjusting mechanism (28) which is pivotable about the axis (O) of the backing roll, whereby the distance between the fountain (5) and the metering element (7) may be adjusted. A fountain coater as claimed in Claim 5 characterised in that the dwell time adjusting mechanism comprises a dwell time adjusting bracket (13) at each end of the backing roll (2) which is pivotable about the axis (O) of the backing roll (2) and an actuator (14) connected to the dwell time adjusting brackets (13) to pivot them about the axis (O). A fountain coater as claimed in Claim 6 characterised in that the drive journal (33) of the backing roll (2) is surrounded by a bush (35) which is supported by a support frame (36), the bush and support frame being divided into upper and lower bush portions (35a, 35b) and upper and lower support frame portions (36a, 36b), respectively, the lower support frame portion (36b) being fixed to the main frame (1) of the fountain coater, the upper support frame portion (36a) being hingeable between open and closed positions in relation to the lower support frame portion (36b) and that a slide member (37) of substantially U-shaped section is received in the bush (35) for sliding movement, the dwell time adjusting bracket (13) of the dwell time adjusting mechanism on the drive side of the backing roll being suspended from the lower portion of the slide member (37).

Inventors: HITOMI TAKESHI, ISHIZUKA KATSUMI, MORITA HIROFUMI, NAKAZAWA TAKEO, HITOMI, TAKESHI, ISHIZUKA, KATSUMI, MORITA, HIROFUMI, NAKAZAWA, TAKEO
Applicants: ISHIKAWAJIMA HARIMA HEAVY IND, ISHIKAWAJIMA-HARIMA JUKOGYO KABUSHIKI KAISHA
Application year: 1991
Main classification: B05C5
IPC codes: B05C5