Dual lane coating

Abstract

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.