WEB FEEDER WITH CONTROLLED ELECTROSTATIC FORCE AND METHOD

Abstract: A method and apparatus for applying a uniform electrostatic force to a web (3) moving between a pair of electrodes (10, 11) to create an electron wind that urges the web (3) toward one of the electrodes (10, 11) controls the current forming the electron wind to maintain the current and the wind force substantially constant even through impedence may vary. The method may be used to provide a hard nip, to adjust tension, to spread and/or to smooth a coating, to remove curl, and to cure a coating.

Description: Title: WEB FEEDER WITH CONTROLLED ELECTROSTATIC FORCE AND METHOD TECHNICAL FIELD This invention relates generally, as is indicated, to apparatus and method for applying electrostatic force and web processing and moving equipment which use electrostatic force and related methods, and, more particularly, to apparatus and method for accurately controlling and applying electrostatic force, sometimes referred to as a corona wind or electron wind, to sheet material and the like and methods of handling, processing, treating, and moving such material. BACKGROUND When feeding a web of flexible non-metallic material, such as an elongate sheet of paper, plastic, fabric, etc., for various purposes, such as to apply a coating thereto, to cure a coating thereon, to print thereon, etc., the web is pulled from a supply or source, such as a storage drum or reel or some other supply source, or is otherwise moved along a path. Usually one or more rolls or the like support the web as it is moved along a path and one or more drive rolls (also referred to as a "pull roll") pull the web along that path. Often it is desirable to provide relatively strong engagement or frictional engagement of the web and the surface of a drive roll to avoid slippage therebetween. Such slippage can result in non-uniform speed of web movement along the path, and such non-uniformity may detrimentally affect the web, the coating or the like applied to the web, etc. For example, such non- uniform speed can result in non-uniform coating of the web, non-uniform curing of the coating material, wrinkles, folds, and/or tears in the web, and so on. Therefore, often it is desirable to maintain a controlled or adjustable uniform speed of travel of a web through coating equipment, heating or curing equipment, and/or other equipment. However, the speed of travel may tend to change as the diameter of the supply reel and/or the take up drum or reel changes when the web is transferred from one to the other. As those changes occur, the force required to maintain tension on the web and/or to maintain the pulling force on the web may vary. Various techniques have been used to hold the web to a pull roll used to move the web along the path. One technique is to use one roll, such as an idler roll, to press the web against the pull roll. The idler roll may be located in direct SUBSTITUTE SHEET (RULE 26} confronting engagement with the pull roll separated from it only by the web or the idler roll may be relatively upstream or downstream of the pull roll to urge the web into engagement with the pull roll; in either case the idler roll usually engages a surface of the web opposite the surface which is engaged by the pull roll. There are several disadvantages to using such idler roll technique, two of which are, as follows: the idler rolls add to the size, expense, and mechanical servicing requirements of the equipment; and sometimes it is especially undesirable for a roll surface, such as that of an idler roll, to engage the mentioned "opposite" surface of the web, for example, such surface being one on which a coating or the like has been applied and has not yet cured. The engagement of the idler roll with such a coated surface may damage the coating and/or may result in damaging of the idler roll, for example, in the event coating material were to stick to the idler roll itself. Idler rolls and/or drive rolls also have been used to form a hard nip between two rolls. A hard nip tends to isolate the relatively upstream and downstream portions of the web relative to each other for various purposes. However, use of more rolls for a hard nip also encounters several of the disadvantages mentioned above. For example, it has been found in one prior web processing machine, to obtain a hard nip for isolating portions of a web moving through the machine between a drive roll and a nip forming roll, such as an idler roll, can require approximately 3 to 5 horsepower (2,100-3,500 watts) energy to move the drive roll of such a hard nip. It would be desirable to be able to provide a hard nip without requiring such large amount of energy. A vacuum technique also has been used in the past to hold a web to a pull roll. For example, the pull roll may have openings in the surface, and those openings are connected to a vacuum source. The vacuum at those openings draws the web to the pull roll. However, such vacuum techniques are complex and expensive. An electrostatic technique also has been used in the past to provide relatively strong engagement between a web and the surface of a pull roll without the need to touch the surface of the web opposite the surface which is engaged with the pull roll. An example is described in U.S. Patent No. Re. 26,951, the entire disclosure of which hereby is incorporated by reference. Using such an electrostatic technique, a charge of static electricity is applied to the web as it travels along its path, and that charge causes a force which urges the web against the surface of the drive roll. In one such system the drive roll is electrically conductive and a corona discharge device spaced apart from the drive roll provides a static electricity discharge toward the web and drive roll urging the web against the drive roll. An electrostatic system also has been used in the past to apply tension to a web by using the electrostatic force to urge the web against an electrically conductive brake bar; by varying the strength of the electric field produced between the source of electrostatic energy and die brake bar, for example, a drag force of correspondingly varying magnitude can be applied to the web. In prior electrostatic systems of the type mentioned above the actual force applied to die web varies as various parameters change. The electrostatic derived force applied to the web depends on the current which flows between the electrostatic charge-supplying device and the drive roll or brake bar; and as resistance changes, the current also may change. Such resistance changes may occur due to changes in the gap or spacing between the static charge supplying device and the electrically conductive drive roll or brake bar, for example; and such resistance changes also may be due to changes in ambient humidity, moisture content of the web, composition of the web, thickness of the web, undulations in the web, coating material on the web, etc. The variation in current and, thus, force with which the web is urged into engagement with the drive roll or brake bar can result in slippage of the web relative to the drive roll, change in tension, change in time that a web is located in heating or other curing equipment, change in thickness or amount of coating applied to a surface of the web, etc., each of which can reduce the quality of the finished web product. Sometimes a coated web is directed through a heated area, such as an oven, in which elevated temperature tends to cure the coating. It is desirable to maintain the uniform speed of a web during coating and curing, for if the web remains too long in the oven, the coating may be non-uniformly cured and/or it or the web itself may be burned. If the web is not in the curing zone of the oven, the coating may not sufficiently cure. These curing problems also may occur when means other than heat is used to induce or to assist curing. SUBSTITUTE SHEET (RULE 26 Usually it is desirable to provide uniformity in the distribution of coating material on a surface of a web. The coating may be applied, for example, by a roll which picks up the coating material from a reservoir and applies the coating material to the web surface. However, non-uniformity of the coating can be caused by an imperfection in the application roll, dirt in the reservoir supply, and/or irregularities in the web surface to which the coating is to be applied. The non-uniformity may be due to placing of coating at only some, but not all locations on the web or due to roughness in the coating or uneven thickness or distribution of the coating. Accordingly, there is a need in the art to improve the uniformity in the coating applied to a surface of a web or other sheet material, especially when that web or sheet material is moving continuously. In accordance with the invention, then, one aspect relates to a method of applying an electrostatic force to a moving web, comprising moving a web in a space between at least one pair of electrodes, supplying a voltage to the electrodes to cause a flow of electrons in the space between the electrodes to apply an electrostatic force to the web, and controlling die current flowing between the electrodes thereby to control the electrostatic force. Another aspect relates to a method for applying a controlled force to a web, comprising directing an electric current between a source of electrostatic energy and an electrically conductive member to create an electrostatic force to urge a web toward such member, and controlling the current of such source to maintain a desired electric current in said directing step thereby to control the force applied to such web. A further aspect relates to apparatus for applying electron wind to a material, comprising a plurality of electrodes having a space therebetween, means for supplying current to the electrodes to cause an electron wind in the space, and means for controlling the current to maintain die electron wind substantially constant as the electrical impedance in the space may vary. An additional aspect relates to a method for applying a controlled corona wind to a material for maintaining a constant force on the material, comprising directing a corona wind toward die material, and controlling the current of the corona wind to maintain a substantially constant current of the corona wind thereby to maintain a desired substantially constant force on the material although the electrical impedance in the path of the corona wind may vary. Even another aspect relates to a method of controlling tension in a web travelling along a path, comprising directing a corona wind toward web to urge die web against a surface, and adjusting die current flowing in the corona wind thereby to control force urging the web against such surface. Even a further aspect relates to a method of spreading or smoothing a coating located on a surface, comprising applying a corona wind to the surface with sufficient force to distribute die coating on the surface. Even an additional aspect relates to a method of avoiding distortions in a moving web, comprising applying an electrostatic force to a web to urge it into engagement with another surface to resist movement and, thereby, to create a tension in the web, and controlling the force with which the web is urged into engagement thereby to control the tension and to maintain the length characteristics of the web substantially constant over the widdi thereof. Yet another aspect relates to a method of removing curl from a paper-like web of material travelling along a path, comprising applying moisture to the web, and stretching the web between a drive roll and a relatively hard nip, and forming the relatively hard nip by applying an electrostatic force between a source of electrons and an electrically conductive member to urge the web toward such member. Yet a further aspect relates to a method of controlling the dimensionality of a web travelling along a path, comprising stretching the web between a drive roll and a relatively hard nip, and forming the relatively hard nip by applying an electrostatic force between a source of electrons and an electrically conductive member to urge the web toward such member. Yet an additional aspect relates to a method of curing a coating on a web, comprising applying a controlled electrostatic energy field to die web and coating to effect curing of the coating. To the accomplishment of the foregoing and related ends, die invention, then, comprises the features hereinafter fully described and particularly pointed out in die claims. The following description and the annexed drawings set forth in detail certain illustrative embodiments of die invention. These embodiments are indicative, however, of but several of the various ways in which the principles of the invention may be employed. Although the invention is shown and described with respect to the embodiments below, it is obvious that equivalents and modifications will occur to others skilled in the art upon the reading and understanding of die specification. The present invention includes all such equivalents and modifications, and is limited only by die scope of the claims. BRIEF DESCRIPTION OF THE DRAWINGS In the annexed drawings: Fig. 1 is a schematic illustration of a web processing machine in which a coating is applied to a moving web and a controlled electrostatic force or electron wind is used in accordance with the present invention; Fig. 2 is a schematic electric circuit diagram of an apparatus for applying electrostatic wind to material, such as a web, in accordance with the present invention and as is also illustrated in Fig. 1; Fig. 3 is a graph depicting a pulsating DC voltage useful, for example, in the circuit of Fig. 2; Fig. 4 is a schematic illustration of a method according to the invention for smoothing a coating on a web; Fig. 5 is a schematic illustration of a method according to die invention for spreading a coating on a web; Fig. 6 is a schematic illustration of a method according to the invention for curing a coating on a web; Fig. 7 is a schematic illustration of a method according to the invention for removing dimensional irregularities in a web; Fig. 8 is a schematic illustration of a method according to d e invention for removing curl in a web; Fig. 9 is a schematic illustration of an electrostatic force applying system according to the invention for providing both tension and anti-slipping function; Fig. 10 is a schematic illustration of an alternate embodiment of die invention in which a reflector is used to reflect electron flux/electrostatic charge; and Fig. 11 is a schematic illustration of another alternate embodiment of die invention in which a plurality of first electrodes are used to supply the electron wind toward a second common electrode. DESCRIPTION Referring, now, in detail to the drawings, wherein like reference numerals designate like parts in the several figures (and letter and primed suffixes designate similar parts corresponding to parts without such suffix, e.g., 11, 11a and llj'), and initially to Fig. 1, a controlled electrostatic force applying apparatus 1 (sometimes hereinafter referred to as "electrostatic apparatus" or simply as "apparatus" for brevity) in accordance with the present invention is shown with or in conjunction with a web processing machine 2 which applies a coating to a web 3. The web processing machine 2 is exemplary of a system in which the electrostatic system 1 may be used. The coating applied to die web 3 may be, for example, an adhesive coating, ink, some other printing or indicia, waterproofing, etc. It will be appreciated that die apparatus 1 may be used not only in conjunction witii a web coating machine 2 but also for other purposes in which a material, usually sheet material, and preferably moving sheet material, is otherwise or additionally processed, manufactured, etc. The apparatus 1 may be used widi other types of material, too, if desired, to take advantage of die operating characteristics and functions of die apparatus 1. As is shown in both Fig. 1 and Fig. 2, die controlled electrostatic force applying apparatus 1 includes a pair of electrodes 10 (10a and 10b in Fig. 1), 11 (11a and lib in Fig. 1) that are spaced apart from each other establishing a space or gap 12 (12a, 12b in Fig. 1) in which a web 3, for example, may be placed and moved. The apparatus 1 also includes a source or supply of electrical energy 13, which is connected in a circuit 14 with die electrodes 10, 11. The circuit 14 (14a, 14b in Fig. 1) includes me electrical supply 13, electrical conductor, lead or path 15 (15a, 15b in Fig. 1), the electrode 10, die space 12, the electrode 11, and a further electrical conductor, lead or padi 16 (16a, 16b in Fig. 1). Electrical supply 13 may include a battery or some other electrical supply widi an appropriate controller that provide a voltage V across the electrodes 10, 11 via die conductors 15, 16, and d e supply 13 also provides a current I to flow in the circuit 14. The electrode 10 may be tungsten, tungsten alloy or some other electrically conductive material. The electrode 10 may be a wire or wire-like material to provide sufficient field concentration and distribution of electrons flowing in the space 12 relative to the electrode 11. The electrode 11 may be a metal bar, such as a steel or some other electrically conductive material. Since the web 3 may be urged into engagement with the electrode 11 die electrode should have sufficient strength, durability, stiffness, and wear characteristics to avoid damage during or as a result of use. The electrodes 10, 11 may be of other material or shape, one example being presented in the above-mentioned reissue patent. The current I will be a function of die voltage V divided by diat resistance or impedance in die circuit 14. A significant part of that impedance is identified as a resistance R shown in Fig. 2, which exists in the space 12 between the electrodes 10, 11. That resistance R may change from time to time due to changes in die ambient humidity, temperature, moisture content of the web 3, other impedance characteristics of the web 3, thickness and/or distortion of die web 3, coating on the web 3 and/or thickness of die coating, distribution of die coating, other non- uniformities in die coating, etc. The electrostatic field, ion or electron flow or current flowing in die space 12 causes there to be what is known as an electron wind or corona wind which applies a force to the web 3 urging it against or toward one of me electrodes. As die mentioned resistance R changes, in prior devices d e current I also would change. Since die electrostatic force or electron wind applied to die web 3 is a function of die current I, a change in the resistance R will change that force which resulted in non-uniform force, which can result in non-uniform operation and/or output web product, in prior devices. The controlled electrostatic force applying apparatus 1 of the invention provides for control of the current I and, dierefore, the force, for example, to maintain diem constant at a prescribed or set level. Accordingly, die electrical supply 13 is a variable one. The current flowing in the circuit 14 is measured or monitored by a conventional meter or other sensor 17 to provide a feedback signal for controlling the electrical supply 13 to maintain a constant desired current I. The electrical supply 13 may include a variable DC voltage source or supply 20, for example, which is coupled to a controller 21. The controller 21 is connected to the meter 17 by a connection 22 and responds to die measured value of die current I to provide an adjustment of die voltage V provided by die voltage supply 20 so that the current I is maintained substantially constant even though the resistance R in the space 12 may vary. An input 23 to die controller 21 may be used to determine a set point, level or magnitude for die current I and die electrostatic force resulting from me electron wind or corona wind between die electrodes 10, 11. The input 23 may be a voltage level input representing a desired force, or some other input to which me controller 21 responds to maintain the current I at a corresponding constant level. An exemplary input 23 may be provided from an electrical source, such as a battery, and an adjustable potentiometer 24 to provide a signal representing the set point, i.e., the desired magnitude, of the current I. For example, such set point determining signal may be a set point current I s , which is provided to die controller 21 and is compared widi a signal representing the actual current I, thereby to cause the controller 21 and source 20 to provide an output that causes die current I to be maintained constant as a function of die magnitude of die set point current I j . The source 20 and controller 21 may be conventional electrical or electronic components (or component). For example, such components may be of the type which responds to a feedback signal representing the actual current I and die set point current I s . An example would be an amplifier which receives the set point signal I j and a negative feedback signal representing die current I as respective inputs. The two signals would be compared in a comparator and die result of die comparison would be used to increase or to decrease die voltage of the source 20, for example, to maintain the current I constant. In Fig. 2 the voltage supply 20 is shown as a variable voltage source or variable battery, and die voltage V output provided thereby is variable according to die control by die controller 21. To provide die desired electron wind, it is desirable tiiat die voltage V be a DC voltage. However, in many instances the polarity of the voltage is not critical, i.e., it could be positive or negative. As is shown in Fig. 3, the voltage V may be a pulsed DC voltage in which the amplitude of each voltage pulse 25 is W 1 and die pulses are occurring at intervals on the order of 40 nanoseconds to 60 nanoseconds widi a duty cycle of approximately 50%, i.e., 50% on and 50% off. A non-pulsating DC voltage also may be used. Other forms of DC voltage also may be used consistent widi die principles of the invention. In the embodiment of the invention illustrated in Figs. 1 and 2, for example, the electrode 10 is coupled to die positive side of die electrical supply 13, and die electrode 11 is coupled to die negative or relative ground side or terminal 26 of die electrical supply 13. When the electrical supply 13 provides voltage across the electrodes 10, 11 and current I flows in die circuit 14, there is a flow of electrons between the electrodes 10, 11. Sometimes that electron flow is referred to as a flow of ions, and sometimes it is referred to as an electrostatic discharge, corona, etc. Regardless of die label applied to such phenomenon, mere is effectively a flow of electrons between the electrodes 10, 11 across die space 12 tending to cause what is referred to sometimes as an electron wind or a corona wind. In die embodiment illustrated in Figs. 1 and 2, such electron wind, which is designated at 27 in Fig. 2, for example, tends to urge die web 3 toward one of die electrodes, and in such embodiment toward die electrode 11. The force of the electron wind on die web 3 is a function of die magnitude of die current I. By maintaining the current substantially constant, the force can be maintained substantially constant. As is seen in Fig. 1, the web processing machine 2 includes two apparatuses 1, respectively, on each side of a processing zone 30 through which d e web 3 is moved in die direction of die arrow 31. The web is supplied from a supply reel 32 which rotates about an axle 32a, for example, is moved along a path in the direction of die arrows 31, and is taken up or stored on a take up drum or reel 33. In die processing zone 30 a coating system 34 applies a coating to a surface 3a of the web 3. The coating system includes a reservoir 35 containing a coating material 36 tiiat is applied by a coating roller 37 to die web surface 3a. An equalizer bar, idler roll or die like 38 also may be included in die coating system 34 for usual purposes. Although the coating system 34 in the processing zone 30 is shown to be of a particular form, it will be appreciated tiiat many otiier types of coating systems and/or otiier processing apparatus for processing the web 3 may be used. The exemplary coating system 34 may apply an adhesive, ink, waterproofing material, or other material as a coating or some other type of treatment to the web 3, for example. In die processing zone 30 there also may be included curing apparatus, heating apparatus, and/or otiier apparatus for treating or otherwise affecting the web 3, as is schematically shown at 39. The web processing machine 2 also includes at least one drive mechanism 50 for moving the web 3 from the supply drum 32 through the processing zone 30 to the take up drum 33. The drive mechanism 50 includes a drive roll 51, which is rotated (turned) by a motor or other mechanism 52 coupled to a drive shaft 53. The drive roll 51 pulls die web 3 from the supply reel 32 through the processing zone 30. In the illustrated embodiment the drive roll 51 engages die surface 3b of the web 3 opposite the coated surface 3a; but, if desired, die drive roll may engage the coated surface. The take up reel 33 may be driven to take up the web 3 thereon and to pull die web from the drive roll. One or more of the otiier rolls shown in die apparatus 2 also may be driven. Furthermore, additional rolls and/or additional processing zones, curing zones or coating or otiier processing equipment in the processing zone 30 or separate from the processing zone 30 may be included in die machine 2. In the illustrated embodiment of Fig. 1 die drive roll 51 may be used as an electrode of d e apparatus 1. For example, the drive roll 51 may be electrically conductive or at least include an electrically conductive layer 54, which may be at the surface or below the surface thereof. In Fig. 1 such electrically conductive layer 54 is shown at die surface of the drive roll 51 and it serves as electrode 11a. The electrically conductive layer 54 (or the entire drive roll 51 if it is conductive) is connected to the ground connection 26 of die electrostatic apparatus circuit 14, as is illustrated. The controlled electrostatic force applying apparatus 1, as is shown in Fig. 1, includes two electron wind generating portions 60, 61 (also referred to as force applying portions), each with a respective electrostatic electrical energy supply 13a, 13b. Alternatively, a combined electrical supply may be used wid appropriate controls to obtain the desired constant current function described herein. Portion 60 includes a wire electrode 10a supported by one or more support or mounting devices 62, such as die schematically illustrated brackets or die like. The wire electrode 1 la is electrically connected by conductor 15a to die controlled electrostatic energy supply 13a. In operation of the electrostatic apparatus 1, a voltage is supplied between the electrode 10a and die electrode 11a (e.g., surface 54) causing a controlled electric current to flow through the space 12a in turn causing an electron wind to urge die web 3 into engagement widi die drive roll 51. As that electron wind and corresponding force are increased, as is determined by die set point of the supply 13a in response to the set point adjustment 23, the force with which the web is urged into engagement with the drive roll 51 and die permitted slippage between the drive roll and die web can be adjusted or controlled. When it is desired tiiat there be minimal slippage (preferably no slippage) the electrostatic apparatus 1 may be set to provide a relatively high current level and electron wind developed force, and vice versa. The portion 60 also may provide a hard nip 60a to isolate the portions of the web 3 respectively upstream and downstream of die hard nip. A comparison of die hard nip 60a and die hard nip provided by a pair of rollers, which is mentioned in die background above, demonstrates die substantial energy savings using die invention. In particular, it has been found in on example, which is not intended to be limiting, that the voltage of the circuit 14 may be at about 30 kilovolts to about 80 kilo volts, and die current I is about 0.1 milliamp or less. Therefore, the energy required to obtain the hard nip using die apparatus 1 of die invention may be on the order of from about 1 watt to about 3 watts, which is far smaller than the energy required in prior art systems. It also has been found in one example of use of the invention that when directing a current flow between plural electrodes, one of which is a wire-like material, to create an electrostatic force urging the web against the other electrode a force on the order of about 3 pounds per linear inch of the web can be obtained. This example is not intended to be limiting. The electrostatic apparatus 1 further electron wind force applying portion 61 includes a wire electrode 10b and a grounded electrode 1 lb coupled widi respect to electrical supply 13b. The wire electrode 10b is mounted on a mounting device 64, such as the schematically illustrated bracket or die like, and is coupled by conductor 15b to die electrostatic energy supply 13b. The electrode 1 lb is connected to ground 26. Upon application of a voltage between die electrodes 10b, lib, a controlled electric current flowing tiierebetween causes an electron wind and force to urge die web 3 against die confronting surface 65 of the electrode lib. By adjusting die set point using the control 23, the force with which die web is urged against the electrode lib surface 65 can be set, and die circuit 14 maintains that force substantially constant. The electron wind force applying portion 61 may be used as a brake to resist the movement of the web 3 toward die drive roll 51. By increasing the electron wind, die force with which die web 3 is urged against die electrode lib can be changed; die greater the force, die greater the friction between the electrode 1 lb and die web 3, and die greater the braking force, and vice versa. The electron wind force applying portions 60, 61 can be operated so that they cooperate to adjust die tension in that portion of the web 3 which is located between them. When the force applied to die web by both of those portions is increased, die tension in the web is increased. If die force applied by die system 60 is at maximum to avoid slippage as die web is pulled by die drive roll 51, tension can be changed by changing the force applied by die force applying system 61. Under appropriate circumstances, for example, when the force applied by die portion 61 is relatively small, tension also may be varied by adjusting die portion 60 and die corresponding slippage of the web 3 relative to die drive roll 51. In using the web processing machine 2, web material 3 is pulled from die supply reel 32 through the electron wind force applying apparatus portion 61 and tiirough the web processing zone 30 by the drive system 50. The electron wind force applying apparatus portion 60 urges the web 3 against die drive roll 51. The take up reel 33 takes up the coated web from die drive roll 51. The coating system 34 applies a coating to a surface 3a of die web 3 and die curing apparatus 39 heats or otherwise cures the coating. The electron wind force applying apparatus portion 61 can apply a controlled force to the web passing therethrough to apply tension or otherwise to affect the web .and its movement in the machine 2. Even as die conditions in respective spaces 12a, 12b of the portions 60, 61 may vary, e.g., due to changes in humidity, coating, web material, etc., the respective electron wind forces remain substantially constant as set to respective set points as is elsewhere described herein. In Fig. 4 is illustrated a portion of a modified processing zone 30a. The modified processing zone 30a may be a portion of die machine 2 or of some other machine in which an electron wind apparatus 1 in accordance widi die invention is used to smooth a coating 70 on a surface 3a of a web 3. The processing zone 30a may be located downstream of die coating system 34, which may be used to apply die coating 70 to die web. Also, the processing zone 30a may be located upstream of the curing apparatus 39 so tiiat the coating 70 may be smoothed before it is cured; however, if desired, die processing zone 30a at which the coating is smoothed may be located downstream of die curing apparatus 39. As is seen in Fig. 4 a portion 70a of the coating 70 is relatively rough or undulating after having been applied to die web 3 by die coating system 34. The apparatus 1 directs die electron wind from an electrode 10c toward die electrode 1 lc and, in particular, toward die coating. The electron wind 27 tends to smooth the coating 70 resulting in a smooth coating 70b relatively downstream of die apparatus 1. The electron wind 27 urges die web against die electrode lie and simultaneously tends to smooth die coating 70. The magnitude of die electron wind can be adjusted by the set point adjustment 23 to obtain die desired smoothing effect. Often it is desirable that a coating be relatively smooth for uniformity of the finished product. The extent of smoothing can be a function of die magnitude of the electron wind. The apparatus in Fig. 4 maintains the electron wind 27 substantially constant, such magnitude being determined by die set point 23. Therefore, the extent of smoothness of die coating 70b also will tend to be constant. However, it is possible that the thickness of die coating 70 may vary, for example, due to undulations in die coating as is seen in die coating portion 70a. Such changes in thickness may affect the impedance or resistance R in die space 12, which, absent the current control and force control provided by die apparatus 1, would result in a variation in force, and, therefore, a variation in die extent of smoothness in die coating of 70b. The present invention accommodates such changes in resistance R, and, accordingly, maintains a constant current I, constant force of electron wind 27, and, therefore, substantially constant extent of smoothness of the coating 70b. The apparatus 1 is shown in Fig. 5 for providing a spreading function. The apparatus 1 is located at a further processing zone 30b shown relatively downstream of die coating system 34 of the machine 2. The further processing zone 30b may be upstream, which is preferred, or downstream of die curing apparatus 39. The -15- processing zone 30b may be in addition to, in place of, or as part of the smoothing apparatus 1 shown at processing zone 30a in Fig. 4. a s is seen in Fig. 5, the coating 71, which is applied to die web 3 may be somewhat non-uniformly distributed on die surface 3a of the web. Such non- uniformity is especially evident at die location 71a relatively upstream of the apparatus 1 at the zone 30b. Such non-uniformity is represented schematically by a somewhat blotchy arrangement of dots depicting coating material on the web 3. The electron wind 27 represented by arrows in Fig. 5 from the electrode lOd toward die electrode lid both tirges the web 3 toward die electrode lid and tends to spread or to distribute die coating material 36 on the web so the coating is more uniformly distributed on die web surface 3a, as is indicated at coating area 71b. By changing die magnitude of die electron wind 27, for example, by altering the set point provided at 23 to die circuit 14 of the apparatus 1, the extent of spreading can be controlled. A larger electron wind will cause greater spreading action, and vice versa. By maintaining the current I and die electron wind force 27 substantially constant, the extent of spreading can be substantially constant thereby to maintain a substantially uniform distribution of the coating material over the surface 3a of the web 3, as is indicated at 71b. Therefore, as die amount of coating on the web at any given location may vary, thus varying die resistance R in the space 12, the force of the electron wind nevertheless remains constant, as is determined by die set point 23, for example, and die spreading action remains substantially constant, too. Turning to Fig. 6, use of the electron wind generating apparatus 1 to cure or to contribute in the curing of a coating 72 applied to a web by a web processing machine 2, for example, is illustrated. The components of the apparatus 1 are similar to those described above, including a circuit 14 to supply energization of electrodes lOe, lie to provide an electron wind 27 in the space 12. The apparatus 1 is located at a further processing zone 30c, which may be located downstream of the coating system 34 at the processing zone 30. The apparatus 1 to provide curing at a processing zone 30c may be in addition to or in place of any one of die other processing zones or devices described herein. For example, if used in addition, the SUBSTITUTE SHEET (RULE 2 apparatus 1 may be located either relatively upstream or downstream of another processing zone and apparatus there. The ions or electrons in the electron wind 27, as is shown in Fig. 6, have been found useful to cure or to assist curing of some coating materials. This has been found especially true in instances when die coating is responsive to such an electrical input to under go curing. For example, it has been found tiiat a silicone coating that contains a quantity of platinum will cure in response to such application of electrical energy (electrons) thereto. Although die polarity of the electron wind voltage supply 20 has been found usually to be irrelevant to the operation of the invention, in some instances, such as curing, it is necessary to have a positive polarity, e.g., the electrode 10 is positive relative to die ground electrode 11. In die embodiment of Fig. 6, since die current I and electron wind resulting therefrom can be set at a desired curing set point I s and will be controlled to be substantially constant, then, by the apparatus the curing effect can be maintained substantially constant, even though resistance or impedance in die space 12 may change. Therefore, as the web 3 is moved along die path of die machine 2 in the direction of die arrows 31, proper curing of die coating 72 on die web can be obtained even though such variations in ambient conditions, for example, may vary. Referring to Fig. 7, use of an electron wind generating apparatus 1 to smooth unevenness or other distortions in die web 3 is shown at a processing zone 30d of a web processing machine 2. The apparatus 1 may be the same as the apparatus 1 described above. The processing zone 30d may be located at various places along die patii of travel of the web 3 in die direction of die arrow 31. However, to help assure that die web 3 is relatively smooth and even before it reaches the coating system 34 at the processing zone 30, the apparatus 1 and processing zone 30d may be relatively upstream of die processing zone 30. As is seen in Fig. 7, the web 3 has a wrinkle 74 in it. The wrinkle 74 may be due to a non-uniformity in the material of which die web 3 is formed, which occur especially in relatively inexpensive web material. It may be due to die fact that die web material is longer at one edge than it is at die otiier, and it may be due to some other reason. Preferably the web 3 is uniform when it reaches the processing zone 30 so that the coating applied by die coating system 34 will be as SUBSTITUTE SHEET (RULE 36) uniform as possible or in any event will have the desired characteristics without having to be concerned with unexpected changes in the web material itself. The apparatus 1 at the processing zone 30d applies an electron wind 27 substantially uniformly across the widtii of the web 3. That electron wind, which flows from the electrode lOf toward die electrode llf tends to urge die web into engagement widi die electrode llf causing some degree of friction and/or tension. Also, that electron wind tends to .smooth out the wrinkle or undulation 74 in the web so that the web itself is relatively smooth or uniform across its widtii and length when it arrives at the processing zone 30 where it is coated. As a result, die coating can be applied widi consistency and uniformity. Since die electron wind force 27 is maintained substantially constant at the processing zone 30d, die characteristics of die web which has passed die processing zone 30d are substantially uniform. It is possible that die resistance/impedance in the space 12 may change due to changes in die shape of the web 30 passing through the processing zone 30d. For example, die non-linear wrinkle 74 may cause tiiat resistance to change. Since the current I and electron wind force 27 are maintained substantially constant in the apparatus 1 at the processing zone 30d, die wrinkle 74 will be smoothed similarly to smoothing of other wrinkles or non-uniformities in the surface or shape of the web 3; and die web material approaching the processing zone 30 will be substantially uniform. Sometimes a web 3 may have a tendency to curl, as is represented by die arrow 75 in Fig. 8. This may be the case whether the web is of paper material or of some other material. The apparatus 1 may be used to reduce or to eliminate such curl by applying an electron wind force 27 to the web 3 in the manner depicted in Fig. 8. For example, if the web is to be cut into flat sheets after it has passed die apparatus 1 at the processing zone 30e without being rolled up on a reel, die electron wind force 27 can be directed at die web 3 urging it against die electrode 1 lg in such a way that curl is reduced or removed. If desired, die electrode llg may be shaped, for example, curved, in such a way as to assist in removing the curl. Additional treatment may be provided die web to remove such curl. For example, if die web is of a plastic material, heat may be applied by a heater 76 or the like to soften the web material so that the force of the electron wind will act on the softened web material to eliminate or to reduce die curl. Alternatively, if die web 3 is paper material, the web material can be dampened widi water from a water supply 77. The dampened web material then may be subjected to the force of the electron wind at die processing zone 30e, and, if necessary, the web can be dried by a drier 78, such as an air drier, heater, etc. , at a relatively downstream location processing zone 30e. Turning to Fig. 9, a web moving system 80 is shown. The system 80 may be used in a web processing machine 2 described herein or in another machine or device. The web moving system 80 includes a pair of electron wind generating apparatuses la, lb, which cooperate with a drive roll 51a, similar to die drive roll 51 mentioned above or some otiier drive roll, to smootii and/or otherwise to remove wrinkles from a web 3 and to drive die web in a direction of die arrow 31. Relatively inexpensive paper used as web material may tend to have wrinkles in it due to different dimensionality characteristics occurring in the paper, such as variations in length at respective edges, variations in density, tensile strength, etc. The drive roll 51a preferably is electrically conductive or has an electrically conductive layer serving as an electrode llh, which is grounded, as shown at 26. The two electron wind generating apparatuses la, lb preferably share the electrode llh as a common electrode for each. The apparatus la includes an electrode lOh coupled in circuit 14 to provide a controlled electron wind 27h directed toward die web 3 and die electrode llh of die drive roll 51a. The electron wind 27h tends to smooth die web 3 and to remove or to prevent wrinkles and/or other defects due to "baggy" characteristics of die web material. The electron wind 27h tends to keep die web taught and, therefore, to prevent change in length of die web at a particular spot, thus avoiding wrinkles and/or otiier non-uniformities. Preferably the location of the electrode lOh is sufficiently upstream of die drive roll 51a and electrode llh so that die electron wind 27h will apply a force to the web 3 without actually urging the entire web into engagement with die drive roll 51a. However, it also is possible that the apparatus la does cause at least part of the web 3 to engage the drive roll 51a. The electron wind generating apparatus lb includes an electrode 10hM which directs an electron wind 27h' toward die web 3 and electrode llh of die drive roll 51a. The electron wind 27h' in a sense provides a hard nip so that the web is held tightly against the drive roll 51a widi controlled (preferably minimal) slippage. Therefore, the driving force from the drive roll 51a is provided efficiently to the web 3 moving the web in the direction of the arrow 31. Thus, the embodiment illustrated in Fig. 9 shows how a plurality of electron wind generating apparatuses can be used together to provide multiple functions with respect to a web 3 and processing of the web. It will be appreciated tiiat the various functions of respective electron wind generating apparatus and processing zone combinations described above and others that may be conceived may be used in combination in various ways, such as the several described in die description hereof. In Fig. 10 a modified electron wind generating apparatus 100 is shown. The apparatus 100 may be used widi or in place of any of the electron wind generating apparatuses described herein, for example, in a web processing machine 2 and/or with respect to respective mediods of use disclosed herein and other methods, too. The apparatus 100 includes a reflector 101 for reflecting the electron wind from die electrode lOi toward die electrode Hi. The reflector 101 preferably is a dielectric material or some type of electrically non-conductive material. An exemplary material is cardboard. The reflector 101 may be curved or some other shape. In the apparatus 100 the reflector 101 is generally parabolic shape so as to reflect die electron wind 27 in the space 12 efficiently toward die electrode Hi in the manner shown by the dotted lines in Fig. 10. Operation of die apparatus 100 is similar to die operation of the apparatus 1 described above. The electrode lOi supplies electrons or ions into the space 12. Some of those electrons are directed toward die electrode Hi directly from the electrode lOi. The reflector 101 is intended to reflect additional electrons from die electrode lOi toward die electrode Hi thereby increasing die number of ions or the electron flux and, therefore, die electron wind compared to die magnitude tiiereof when no reflector is used. It has been found that the reflector 101 tends to increase the electron flux and, tiius, the electron wind by approximately 20% relative to the apparatus 1 in which no reflector is used. The reflector 101 alternatively may be electrically conductive. However, such a conductive reflector may drain energy from die electron wind. Therefore, it usually is advantageous to use a dielectric material for the reflector in order to avoid draining energy from the apparatus 100 that would reduce the electron wind. Anodier embodiment of electron wind generating apparatus 110 is shown in Fig. 11. The apparatus 110 is similar to the apparatus 1 described above and may be substituted therefor in the various embodiments of die machine 2 described herein or in other embodiments, machines or systems. However, die apparatus 110 includes a plurality of electrodes 10, for example, a pair of electrodes lOj and 10jM which are coupled in the circuit 14 to develop an electron wind directed toward die electrode llj. The electrodes lOj and 10j' preferably are coupled in electrical parallel relation by a connection 111 so that die electron wind 27 supplied by each electrode toward die common electrode llj is approximately the same. The current I supplying electrons to die respective electrodes lOj, 10j' will divide approximately evenly and will be maintained substantially constant by the circuit 14 in the manner described above widi respect to the apparatus 1. By increasing the number of electrodes lOj, 10j', etc., the electron wind force 27 can be distributed over a larger area of die material located in the space 12 of the apparatus 110. It will be appreciated that the various embodiments of electron wind generating apparatus 1 disclosed herein may be used for a variety of purposes, such as those described and otiiers, too. The electron wind generating apparatus enables the application of force, curing input, etc., to a web material without detrimentally affecting the characteristics of die coating on die web material. Also, force may be used to improve die web itself for coating and/or die coating itself. The time in a curing zone can be relatively accurately controlled because of control of slippage as a web is driven along a path in a web processing machine, and in some instances electron wind and die electrons thereof may be used to provide for curing, in some instances without having to subject the web to a high temperature environment. It has been found that substantial energy can be saved by using the present invention. For example, prior devices used to obtain a hard nip for isolating portions of a web moving through a web processing machine between a drive roll and a nip forming or idler roll can require approximately 3 to 5 horsepower (2, 100- 3,500 watts) energy to move the drive roll of such a hard nip. In contrast, in one embodiment of die present invention a hard nip, such as tiiat provided by die apparatus lb in Fig. 9 or the apparatus 1 associated widi die drive roll 51 in Fig. 1, may be able to provide such a hard nip function using as little as approximately from 1 to 3 watts of power. Specifically, in one example, the voltage supply 20 provides approximately 30,000 volts and die current is approximately 1 tenth milliamp or less. TFΓHNTΓAT FTF1 P From the foregoing it will be appreciated tiiat die invention provides apparatus and method for coating web material and die like.

Claims: CLAIMS The embodiments of die invention claimed are, as follows: 1. A method of applying an electrostatic force to a moving web, comprising moving a web in a space between at least one pair of electrodes, supplying a voltage to the electrodes to cause a flow of electrons in the space between the electrodes to apply an electrostatic force to the web, and controlling die current flowing between die electrodes thereby to control die electrostatic force. 2. The method of claim 1 , said supplying a voltage comprising supplying voltage from a voltage source, said controlling current comprising measuring current flow from the voltage supply to one of the electrodes, and based on such measurement adjusting die voltage to maintain a desired current. 3. The method of claim 2, said adjusting voltage comprising adjusting voltage to maintain the current substantially constant although die impedance between the electrodes may vary. 4. The method of claim 3, further comprising setting the current to a desired current level that is to be maintained substantially constant. 5. The method of claim 3, said supplying voltage comprising supplying a DC voltage. 6. The method of claim 5, said supplying a DC voltage comprising supplying a pulsed DC voltage. 7. A method of forming a relatively hard nip in a moving web, comprising the method of claim 3, and directing the electrostatic force to urge the web against one of the electrodes to form die nip. 8. A method of applying tension to a moving web, comprising the method of claim 7, and further comprising applying a pull force to the web relatively downstream of die nip. 9. The method of claim 8, further comprising setting the current level to adjust die tension applied to die moving web. 10. A metiiod of reducing length variations in a moving web, comprising the method of claim 8, and further comprising setting die current level to adjust die tension in die web to stretch the web to maintain substantially uniform length profile across the widtii of die web. 11. A metiiod of removing curl in a web comprising the method of claim 8, and further comprising applying moisture to the web upstream of the location at which the electrostatic force is applied, applying the pull force to the web to apply tension thereto, and removing moisture from the web. 12. The method of claim 11, said removing moisture comprising heating the web. 13. The method of claim 11, said removing moisture comprising evaporation. 14. A metiiod of smoothing a coating on a web comprising the method of claim 3, and further comprising applying a coating to the web upstream of the location at which the electrostatic force is applied, and setting the current of the electrostatic force to smooth die coating. 15. A method of spreading a coating on a web comprising d e metiiod of claim 3, and further comprising applying a coating to die web upstream of the location at which the electrostatic force is applied, and setting the current of the electrostatic force to spread die coating on die web substantially uniformly on the web. 16. The method of curing a coating on a material, comprising die metiiod of claim 1 , and further comprising applying to die web, at a location upstream of the location at which die electrostatic force is applied, a coating material which is susceptible to curing in response to application of ions thereto. 17. The method of claim 16, further comprising selecting the coating material as silicone with a platinum ingredient responsive to application of ions thereto to undergo curing. 18. A method for applying a controlled force to a web, comprising directing an electric current between a source of electrostatic energy and an electrically conductive member to create an electrostatic force to urge a web toward such member, and controlling die current of such source to maintain a desired electric current in said directing step tiiereby to control die force applied to such web. 19. The method of claim 18, said directing comprising supplying a DC voltage between a pair of electrodes, one of which comprises at least part of such member, such that such desired electric current flows between the electrodes to create a corona wind that provides die force to urge such web toward such member. 20. The method of claim 19, said controlling the current comprising adjusting die DC voltage to maintain the electric current substantially constant while the impedance in die circuit path between die electrodes may vary. 21. The method of claim 20, wherein the electrodes are spaced apart and said adjusting comprises adjusting die voltage to maintain substantially constant current flow to maintain substantially constant force while the electrical impedance characteristic in die space between the electrodes may vary. 22. The metiiod of claim 21, further comprising measuring the current flow, and based on such measurement adjusting die voltage to maintain substantially constant current. 23. The method of claim 20, said supplying a DC voltage comprising supplying a pulsating DC voltage. 24. The method of claim 20, further comprising using a wire as die otiier of die electrodes. 25. The method of claim 20, further comprising using a grounded electrically conductive plate as such member. 26. The method of claim 20, further comprising moving the web over a roll at least part of which is electrically conductive and comprises at least part of such member, and said directing comprises directing a corona wind from die otiier electrode toward die roll to urge die web toward the roll. 27. The method of claim 18, said directing comprising applying a DC voltage between a pair of electrodes on opposite sides of die web to create a current flow from one electrode to die other electrode, one of such electrodes comprising at least part of such member, and reflecting electron flux from such one electrode to increase die electron flux and die current flow from such one electrode to die other electrode. 28. The metiiod of claim 27, said reflecting comprising using a dielectric reflector. 29. The method of claim 18, said directing comprising applying a DC voltage at a voltage of between about 30 KV and about 80 KV. 30. The method of claim 29, said directing comprising providing an electric current between the electrodes of about 0.1 a. 31. The method of claim 18, said directing comprising directing a current flow between plural electrodes, one of which is a wire-like material, to create an electrostatic force urging the web against die otiier electrode widi a force that is on the order of about 3 pounds per linear inch of the web. 32. The method of claim 18, said directing comprising directing a current flow between first plural electrode means and second electrode means to create an electrostatic force urging the web against die second electrode means. 33. The method of claim 18, said controlling the current comprising maintaining a substantially constant current proportional to a desired force applied to such web. 34. The method of claim 33, further comprising using a voltage source as the source of electrostatic energy, measuring current flow causing the electrostatic force, and based on said measuring adjusting die voltage to maintain substantially constant current flow as the impedance in the circuit path of the current flow may vary. 35. Apparatus for applying electron wind to a material, comprising a plurality of electrodes having a space therebetween, means for supplying current to the electrodes to cause an electron wind in die space, and means for controlling die current to maintain the electron wind substantially constant as the electrical impedance in die space may vary. 36. The apparatus of claim 35, said means for supplying current comprising a voltage source, further comprising means for measuring the magnitude of current that causes the electron wind, and said means for controlling current comprising means for adjusting die magnitude of voltage produced by die voltage source as a function of the magnitude of the measured current to maintain control of die current. 37. The apparatus of claim 35, said means for controlling comprising means for automatically adjusting the current to maintain the current substantially constant. 38. The apparatus of claim 37, said means for controlling comprising means for setting the current level to be maintained substantially constant. 39. The apparatus of claim 35, -said plurality of electrodes comprising a bar-like electrode and a wire-like electrode located in spaced apart and generally parallel relation to each other, said electron wind flowing from the wire-like electrode toward die bar-like electrode to urge die material toward die bar-like electrode. 40. The apparatus of claim 39, said wire-like electrode comprising a plurality of wire-like electrodes spaced apart from each other to avoid interfering with each other and for directing electrons toward die bar-like electrode. 41. The apparatus of claim 35, said plurality of electrodes comprising a roll for transporting the material and a wire-like electrode located in spaced apart and generally parallel relation to each other, said electron wind flowing from the wire-like electrode toward die roll to urge die material toward die roll. 42. A metiiod for applying a controlled corona wind to a material for maintaining a constant force on the material, comprising directing a corona wind toward die material, and controlling the current of the corona wind to maintain a substantially constant current of the corona wind thereby to maintain a desired substantially constant force on the material although the electrical impedance in the path of the corona wind may vary. 43. A metiiod of controlling tension in a web travelling along a path, comprising directing a corona wind toward web to urge the web against a surface, and adjusting the current flowing in the corona wind thereby to control force urging the web against such surface. 44. The method of claim 43, said step of adjusting current comprising maintaining the current substantially constant thereby to maintain the force substantially constant although the electrical impedance in die path of the corona wind may vary. 45. A method of spreading or smoothing a coating located on a surface, comprising applying a corona wind to the surface with sufficient force to distribute die coating on the surface. 46. The metiiod of claim 45, further comprising applying a coating on a web, and moving the coated web through the corona wind. 47. A method of avoiding distortions in a moving web, comprising applying an electrostatic force to a web to urge it into engagement with another surface to resist movement and, thereby, to create a tension in the web, and controlling die force with which die web is urged into engagement thereby to control the tension and to maintain the length characteristics of the web substantially constant over the widtii thereof. 48. The method of claim 45, said applying comprising applying an electron wind to die web. 49. The method of claim 48, said applying an electron wind comprising measuring the current creating the electron wind and maintaining such current substantially constant while the impedance in die path of the electron wind may vary. 50. A method of removing curl from a paper-like web of material travelling along a path, comprising applying moisture to the web, and stretching die web between a drive roll and a relatively hard nip, and forming die relatively hard nip by applying an electrostatic force between a source of electrons and an electrically conductive member to urge die web toward such member. 51. The method of claim 50, further comprising controlling electrical current establishing such electrostatic force thereby to maintain control of the force on the web at the hard nip. 52. A method of controlling the dimensionality of a web travelling along a path, comprising stretching the web between a drive roll and a relatively hard nip, and forming die relatively hard nip by applying an electrostatic force between a source of electrons and an electrically conductive member to urge die web toward such member. 53. The metiiod of claim 52, further comprising controlling electrical current establishing such electrostatic force thereby to maintain control of the force on the web at the hard nip. 54. A method of curing a coating on a web, comprising applying a controlled electrostatic energy field to die web and coating to effect curing of the coating. 55. The method of claim 54, said applying comprising controlling the current of die electrostatic energy field. 56. The metiiod of claim 55, said controlling the current comprising maintaining the current substantially constant during such curing. 57. The method of claim 56, further comprising moving the coated web through die electrostatic field. 58. The metiiod of claim 54, further comprising adding an ingredient to die coating to make the coating susceptible to ions from the electrostatic field so as to enhance such curing. 59. The method of claim 58, wherein die coating material comprises silicone and said adding comprises adding platinum. 60. The method of claim 54, wherein the coating includes an ingredient to make the coating .susceptible to ions from the electrostatic field so as to enhance such curing. 61. The method of claim 54, comprising using a positive DC voltage to form a corona wind as die electrostatic energy field, and said applying comprising applying the corona wind to die web and coating.

Inventors: LAROSE JOSEPH A, PUCCIANI ALLEN STEVEN, LAROSE, JOSEPH, A., PUCCIANI, ALLEN, STEVEN
Applicants: AVERY DENNISON CORP, LAROSE JOSEPH A, PUCCIANI ALLEN STEVEN, AVERY DENNISON CORPORATION, LAROSE, JOSEPH, A., PUCCIANI, ALLEN, STEVEN
Application year: 1996
Main classification: H05F3
IPC codes: B65H23, H05F3