Roll-to-roll slot die coating method to create interleaving multi-layered films with chemical slurry coatings

Biswas, Kaushik; Wood, David Lee; Grady, Kelsey M.; Ghezawi, Natasha B.; Cao, Pengfei; Saito, Tomonori

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Title: Roll-to-roll slot die coating method to create interleaving multi-layered films with chemical slurry coatings

Abstract

An improved method for manufacturing a continuous self-healing barrier film is provided. The method includes slot-die coating opposing sides of a separator substrate with a curing agent slurry and a curable resin slurry using a single-sided coating line or a tandem coating line. The method also includes sequentially interleaving inner and outer protective layers via a continuous roll-to-roll process to create a multi-layered barrier film. The barrier film can optionally be formed into a barrier envelope, and an insulating core material can be inserted into the barrier envelope to define an enclosure. Evacuating and sealing the enclosure along a perimeter of the barrier envelop forms a self-healing vacuum insulation panel with excellent properties for use as a building material and in refrigeration systems, for example. The barrier film can alternatively be used in the manufacture of tires, roofing, cargo containers, food packaging, and pharmaceutical packaging, for example.

Inventors:: Biswas, Kaushik; Wood, III, David Lee; Grady, Kelsey M.; Ghezawi, Natasha B.; Cao, Pengfei; Saito, Tomonori

Issue Date:: Tue Sep 20 00:00:00 EDT 2022

Research Org.:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Org.:: USDOE

OSTI Identifier:: 1925116

Patent Number(s):: 11446915

Application Number:: 16/895,006

Assignee:: UT-Battelle, LLC (Oak Ridge, TN)

Patent Classifications (CPCs):: B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29C - SHAPING OR JOINING OF PLASTICS

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29D - PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE

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B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29C - SHAPING OR JOINING OF PLASTICS
B29C73/22 - the article containing elements including a sealing composition, e.g. powder being liberated when the article is damaged

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29D - PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
B29D7/01 - Films or sheets

B - PERFORMING OPERATIONS B32 - LAYERED PRODUCTS B32B - LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
B32B2037/243 - {Coating}
B32B2038/168 - {Removing solvent}
B32B2250/03 - 3 layers
B32B2250/24 - All layers being polymeric
B32B2255/10 - on synthetic resin layer or on natural or synthetic rubber layer
B32B2255/205 - Metallic coating
B32B2255/26 - Polymeric coating
B32B2305/77 - Uncured, e.g. green
B32B2307/304 - Insulating
B32B2307/7242 - Non-permeable
B32B2307/7244 - Oxygen barrier
B32B2419/06 - Roofs, roof membranes
B32B2439/40 - Closed containers
B32B2439/70 - Food packaging
B32B2439/80 - Medical packaging
B32B2605/00 - Vehicles
B32B27/08 - of synthetic resin {
B32B27/302 - {comprising aromatic vinyl
B32B27/32 - comprising polyolefins {
B32B27/36 - comprising polyesters
B32B37/02 - characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
B32B37/153 - {at least one layer is extruded and immediatly laminated while in semi-molten state}
B32B37/24 - with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate

F - MECHANICAL ENGINEERING F16 - ENGINEERING ELEMENTS AND UNITS F16L - PIPES
F16L59/065 - using vacuum

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02A - TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
Y02A30/242 - Slab shaped vacuum insulation

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02B - CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
Y02B80/10 - Insulation

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DOE Contract Number:: AC05-00OR22725

Resource Type:: Patent

Resource Relation:: Patent File Date: 06/08/2020

Country of Publication:: United States

Language:: English

Citation Formats


                    Biswas, Kaushik, Wood, III, David Lee, Grady, Kelsey M., Ghezawi, Natasha B., Cao, Pengfei, and Saito, Tomonori. Roll-to-roll slot die coating method to create interleaving multi-layered films with chemical slurry coatings.  United States: N. p., 2022. 
        Web.

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                    Biswas, Kaushik, Wood, III, David Lee, Grady, Kelsey M., Ghezawi, Natasha B., Cao, Pengfei, & Saito, Tomonori. Roll-to-roll slot die coating method to create interleaving multi-layered films with chemical slurry coatings.  United States.

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                    Biswas, Kaushik, Wood, III, David Lee, Grady, Kelsey M., Ghezawi, Natasha B., Cao, Pengfei, and Saito, Tomonori. Tue .  
        "Roll-to-roll slot die coating method to create interleaving multi-layered films with chemical slurry coatings".  United States.  https://www.osti.gov/servlets/purl/1925116.

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@article{osti_1925116,

  title        = {Roll-to-roll slot die coating method to create interleaving multi-layered films with chemical slurry coatings},

  author       = {Biswas, Kaushik and Wood, III, David Lee and Grady, Kelsey M. and Ghezawi, Natasha B. and Cao, Pengfei and Saito, Tomonori},

  abstractNote = {An improved method for manufacturing a continuous self-healing barrier film is provided. The method includes slot-die coating opposing sides of a separator substrate with a curing agent slurry and a curable resin slurry using a single-sided coating line or a tandem coating line. The method also includes sequentially interleaving inner and outer protective layers via a continuous roll-to-roll process to create a multi-layered barrier film. The barrier film can optionally be formed into a barrier envelope, and an insulating core material can be inserted into the barrier envelope to define an enclosure. Evacuating and sealing the enclosure along a perimeter of the barrier envelop forms a self-healing vacuum insulation panel with excellent properties for use as a building material and in refrigeration systems, for example. The barrier film can alternatively be used in the manufacture of tires, roofing, cargo containers, food packaging, and pharmaceutical packaging, for example.},

  doi          = {},

  journal      = {},
number       = ,

  volume       = ,

  place        = {United States},

  year         = {Tue Sep 20 00:00:00 EDT 2022},

  month        = {Tue Sep 20 00:00:00 EDT 2022}

}

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Works referenced in this record:

Self-healing UV-barrier coating for flexible polymer substrate
patent, August 1998

Sanders, Michael L.; Rowlands, Scott F.; Coombs, Paul G.
US Patent Document 5,790,304
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Humidity-triggered self-healing films with excellent oxygen barrier performance
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Hints for an additional aging factor regarding the thermal performance of vacuum insulation panels with pyrogenic silica core
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Fifteen chemistries for autonomous external self-healing polymers and composites
journal, October 2015

Hillewaere, Xander K. D.; Du Prez, Filip E.
Progress in Polymer Science, Vol. 49-50
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Electrode structure for electrochemical cell
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Burnside, Savannah; Campbell, Christopher; Scordilis-Kelley, Chariclea
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Method for manufacturing electrode for storage battery
patent-application, October 2014

Nanba, Kenryo; Yukawa, Mikio
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Self-healing polymeric materials based on microencapsulated healing agents: From design to preparation
journal, October 2015

Zhu, Dong Yu; Rong, Min Zhi; Zhang, Ming Qiu
Progress in Polymer Science, Vol. 49-50
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Rapid, Puncture-Initiated Healing via Oxygen-Mediated Polymerization
journal, July 2015

Zavada, Scott R.; McHardy, Nicholas R.; Gordon, Keith L.
ACS Macro Letters, Vol. 4, Issue 8
https://doi.org/10.1021/acsmacrolett.5b00315

Self-repairing laminated structure and self-fusing insulated wire
patent-application, May 2014

Araya, Kotaro; Amou, Satoru
US Patent Application 14/131095; 20140141254
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Self-healing environmental barrier coating
patent, April 2018

Hass, Derek D.
US Patent Document 9,951,630
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Roll-to-Roll Coating Technology and Its Applications: A Review
journal, April 2016

Park, Janghoon; Shin, Keehyun; Lee, Changwoo
International Journal of Precision Engineering and Manufacturing, Vol. 17, Issue 4
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FG/FxFG as well as GLFG repeats form a selective permeability barrier with self-healing properties
journal, August 2009

Frey, Steffen; Görlich, Dirk
The EMBO Journal, Vol. 28, Issue 17
https://doi.org/10.1038/emboj.2009.199

Self-Healing Laminate System
patent-application, July 2009

Beiermann, Brett A.; Keller, Michael W.; White, Scott R.
US Patent Application 12/359631; 20090191402
URL: https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/20090191402

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Similar Records

Title: Roll-to-roll slot die coating method to create interleaving multi-layered films with chemical slurry coatings

Abstract

Citation Formats

Self-healing UV-barrier coating for flexible polymer substrate patent, August 1998

Humidity-triggered self-healing films with excellent oxygen barrier performance journal, January 2014

Hints for an additional aging factor regarding the thermal performance of vacuum insulation panels with pyrogenic silica core journal, February 2014

Fifteen chemistries for autonomous external self-healing polymers and composites journal, October 2015

Electrode structure for electrochemical cell patent-application, August 2013

Method for manufacturing electrode for storage battery patent-application, October 2014

Self-healing polymeric materials based on microencapsulated healing agents: From design to preparation journal, October 2015

Rapid, Puncture-Initiated Healing via Oxygen-Mediated Polymerization journal, July 2015

Self-repairing laminated structure and self-fusing insulated wire patent-application, May 2014

Self-healing environmental barrier coating patent, April 2018

Roll-to-Roll Coating Technology and Its Applications: A Review journal, April 2016

FG/FxFG as well as GLFG repeats form a selective permeability barrier with self-healing properties journal, August 2009

Self-Healing Laminate System patent-application, July 2009

Self-healing UV-barrier coating for flexible polymer substrate
patent, August 1998

Humidity-triggered self-healing films with excellent oxygen barrier performance
journal, January 2014

Hints for an additional aging factor regarding the thermal performance of vacuum insulation panels with pyrogenic silica core
journal, February 2014

Fifteen chemistries for autonomous external self-healing polymers and composites
journal, October 2015

Electrode structure for electrochemical cell
patent-application, August 2013

Method for manufacturing electrode for storage battery
patent-application, October 2014

Self-healing polymeric materials based on microencapsulated healing agents: From design to preparation
journal, October 2015

Rapid, Puncture-Initiated Healing via Oxygen-Mediated Polymerization
journal, July 2015

Self-repairing laminated structure and self-fusing insulated wire
patent-application, May 2014

Self-healing environmental barrier coating
patent, April 2018

Roll-to-Roll Coating Technology and Its Applications: A Review
journal, April 2016

FG/FxFG as well as GLFG repeats form a selective permeability barrier with self-healing properties
journal, August 2009

Self-Healing Laminate System
patent-application, July 2009