Potential Investigation on Multiphase Flow of Loaded Dispersion for the Production of Metallized Paper

The current review research's main objective is to develop dispersion models in the multilayer curtain coating with the production of metallized paper. To achieve this, the curtain coating on the paper substrate is employed with respect to multilayer coating of polymers. The first layer of polymer is applied to the paper and then it is subjected to vacuum metallization with aluminum deposition. After it, another second layer of polymer is subjected on it to prevent it from oxidation. These coated polymers are different in nature. The metallized paper will be produced which has high strength will be formulated in this application of curtain coating. The instability of curtain and air entrainment will be minimized from high Weber number, low Reynolds number, Optimum web speed and Coat weights. The above demonstrated process simulation will be modelled in Ansys-CFD. The dispersion of solids in the curtain flow through substrate moving on the web will be evaluated from different numerical methods. Each method has its own characteristics to study the nature of solids dispersion. The high loaded solids dispersion will be investigated from numerical methods including Langrangian Point Particle, Coarse grained molecular dynamics, Stokesian Dynamics, Brownian Dynamics, Point Particle Method Reynolds Averaged Navier Stokes equation, Eulerian Method, Langrangian-Eulerian Point Particle, Large Eddy Simulation point particle, Combined discrete element and Large Eddy Simulation and Discrete Element Methods.

Multifunctional barrier coating systems created by multilayer curtain coating

Functional coatings are applied to paper and paperboard substrates to provide resistance, or a barrier, against media such as oil and grease (OGR), water, water vapor as measured by moisture vapor transmission rate (MVTR), and oxygen, for applications such as food packaging, food service, and other non-food packaging. Typical functional barrier coatings can be created by applying a solid coating or extruded film, a solvent based-coating, or a water-based coating to the paper substrate using various means of coating applicators. This paper focuses on water-based barrier coatings (WBBC) for OGR, water, MVTR, and oxygen barriers. The main goal was to create coated systems that can achieve more than one barrier property using multilayer curtain coating (MLCC). Curtain coating has emerged as the premier low-impact application method for coated paper and paperboard. This paper provides examples using MLCC to create coating structures that provide multiple barrier properties in a single coating step. Barrier polymer systems studied include styrene butadiene, styrene acrylate, vinyl acrylic, and natural materials, as well as proprietary additives where required to give desired performance. The paper also shows how the specific coating layers can be optimized to produce the desired property profile, without concern for blocking, as the addition of a non-blocking top layer can be applied in the MLCC structure as well. Experiments on base sheet types also shows the importance of applying the multilayer structure on a pre-coated surface in order to improve coating thickness consistency and potentially allow for the reduction of more expensive layer components.

Dynamic wetting failure and hydrodynamic assist in curtain coating

Dynamic wetting failure in curtain coating of Newtonian liquids is studied in this work. A hydrodynamic model accounting for air flow near the dynamic contact line (DCL) is developed to describe two-dimensional (2D) steady wetting and to predict the onset of wetting failure. A hybrid approach is used where air is described by a one-dimensional model and liquid by a 2D model, and the resulting hybrid formulation is solved with the Galerkin finite element method. The results reveal that the delay of wetting failure in curtain coating – often termed hydrodynamic assist – mainly arises from the hydrodynamic pressure generated by the inertia of the impinging curtain. This pressure leads to a strong capillary-stress gradient that pumps air away from the DCL and thus increases the critical substrate speed for wetting failure. Although the parameter values used in the model are different from those in experiments due to computational limitations, the model is able to capture the experimentally observed non-monotonic behaviour of the critical substrate speed as the feed flow rate increases (Blake et al., Phys. Fluids, vol. 11, 1999, p. 1995–2007). The influence of insoluble surfactants is also investigated, and the results show that Marangoni stresses tend to thin the air film and increase air-pressure gradients near the DCL, thereby promoting the onset of wetting failure. In addition, Marangoni stresses reduce the degree of hydrodynamic assist in curtain coating, suggesting a possible mechanism for experimental observations reported by Marston et al. (Exp. Fluids, vol. 46, 2009, pp. 549–558).

Coating Onto a Prewet Substrate With Low Weber Number Liquid Curtain

In recent years, miniaturization and high precision of the LCD screen used for small display has been developed fast. The thin and high-precision film covering the LCD screen is manufactured by slide coating. In slide coating, however, the distance between the slot and the substrate is too small. On the other hand, curtain coating can avoid the influence of the mechanical disturbance and is also a good method for coating on rugged substrate. Nevertheless, curtain coating has not been applied to the LCD screen because the liquid curtain with small discharge, i.e. small Weber number, causes instabilities of the flow and the free surfaces. In the present study, we performed the experiment of the liquid curtain bridged between the exit of slot die and moving roller under very small Weber number (We ∼0.1). It is found that the surface waves are reduced by using a roller pre-wetted by mists and by changing the viscosity of the liquid. Also, the coating window can be drawn in a plane of surface tension and viscosity. Finally, we tried to explain these phenomena by analyzing the equations of liquid curtain.