Roll-to-Roll & Precision Coating

Micro-Gravure & Reverse Kiss Coating Calculator

Model micro-gravure cell transfer efficiency, reverse roll speed ratios ($R = V_{\text{roll}}/V_{\text{web}}$), wet/dry laydown thickness, and doctor blade wiping dynamics for battery separators, optical films, and printed electronics.

1. Input Parameters

Gravure Cell Volume (V_cell in cm³/m² or BCM):

Nominal engraved cell volume (1 BCM = 1.55 cm³/m²). Typical: 5 - 35 cm³/m².

Reverse Speed Ratio (R = V_roll / V_web):

Ratio of gravure cylinder peripheral speed to moving web speed (typical: 0.8 - 2.0).

Cell Transfer Efficiency (η %):

Liquid release factor from micro-cells to substrate (typically 35% - 55%).

Coating Solids Content (S %):

Non-volatile polymer or solids percentage by weight in solution.

Web Line Speed (V_web in m/min):

Continuous substrate travel speed through the coating head.

Coating Width (W in mm):

Active coated web width across the kiss contact meniscus.

2. Calculation Results

Wet Film Thickness (t_wet)

6.56 µm

Dry Film Thickness (t_dry)

1.84 µm

Wet Laydown Rate

6.56 g/m²

Liquid Consumption Rate

76.7 mL/min

3. Geometric Visualizer

Tooling & Vector Prepress Engineering Notes

Micro-Gravure & Reverse Kiss Coating Physics: Micro-gravure utilizes a small-diameter (typically 20mm–50mm) engraved roll rotating in reverse relative to web travel with a high-precision trailing doctor blade. The wet film thickness is governed by:

t_wet = η × V_cell × (V_roll / V_web) [µm]
t_dry = t_wet × (Solids% / 100) × (ρ_solution / ρ_dry) [µm]

Vector Cylinder Engraving Requirements: Laser-engraved ceramic or diamond-turned micro-gravure rolls require seamless tileable cell vectors. Tri-helical grooves (45°–60° mesh angle) prevent doctor blade chattering and ribbing instability. Cells must have smooth draft angles (110°–130° included angle) to prevent polymer entrapment.