DUAL LANE COATING
The present invention relates to methods and apparatuses for forming an active-containing film product, while significantly reducing the amount of wasted active material. The resulting product is an active-containing film product that meets the user's predetermined criteria of physical properties and is suitable for use.
1 .- 30 . (canceled)
31 . A method of forming an active-containing film comprising the steps of:
a. providing a first batch of a film forming matrix comprising at least one polymer;
b. providing a second batch of film forming matrix comprising at least one polymer and an active;
c. applying a layer of said film forming matrix from said first batch onto a substrate and forming a film from said film forming matrix from said first batch;
d. optionally, adjusting at least one processing parameter; and
e. applying a layer of said film forming matrix from said second batch onto said substrate and forming an active-containing film from said film forming matrix from said second batch.
32 . The method of claim 31 , comprising measuring the film formed from said film forming matrix from said first batch for at least one physical property.
33 . The method of claim 32 , comprising determining whether said at least one physical property meets predetermined criteria.
34 . The method of claim 33 , comprising adjusting at least one processing parameter after determining whether said at least one physical property meets predetermined criteria.
35 . The method of claim 31 , comprising applying said layer of said film forming matrix from said first batch in a first lane on said substrate and applying said layer of said film forming matrix from said second batch in a second lane on said substrate.
36 . A film forming apparatus comprising:
a. a substrate;
b. an apparatus to feed a first batch of film forming matrix to a first lane on said substrate;
c. an apparatus to feed a second batch of film forming matrix to a second lane on said substrate; and
d. a drying apparatus.
37 . The film forming apparatus of claim 36 , further comprising a coating head.
38 . The film forming apparatus of claim 36 , wherein said lanes are formed by substantially parallel dams.
39 . The film forming apparatus of claim 36 , wherein said drying apparatus is sized to accommodate said substrate.
40 . The film forming apparatus of claim 36 , wherein said substrate is moveable.
41 . The film forming apparatus of claim 40 , wherein said film forming apparatus can switch from feeding said first batch to feeding said second batch while said substrate moves said substrate through said drying apparatus.
42 . The film forming apparatus of claim 36 , wherein the film forming apparatus comprises more than two lanes.
43 . The film forming apparatus of claim 36 , wherein the second lane is substantially parallel to the first lane.
44 . The film forming apparatus of claim 36 , wherein said apparatus to feed said first batch is a coating roller.
45 . The film forming apparatus of claim 36 , wherein said apparatus to feed said second batch is a coating roller.
46 . The film forming apparatus of claim 36 , wherein said apparatus to feed said first batch and said apparatus to feed said second batch is the same coating roller.
47 . The film forming apparatus of claim 36 , wherein said first batch is stored in a first container.
48 . The film forming apparatus of claim 36 , wherein said second batch is stored in a second container.
49 . The film forming apparatus of claim 40 , wherein the speed of a movable substrate is adjustable.
50 . The film forming apparatus of claim 46 , wherein a gap size of said coating roller is adjustable.