Skip to main content
SpringerLink
Log in

High-speed roll coating with complex rheology fluids

  • Research Article
  • Published:
Experiments in Fluids Aims and scope Submit manuscript

Abstract

The flow of high solids content suspensions and coating colors through the deformable gap of counter-rotating rolls at high speed was investigated. Measurements of nip pressure profiles in a laboratory film coater were conducted and flow visualization experiments downstream the nip were carried out. A high-speed video system allowed showing the formation, elongation and break up of filaments that yield the misting droplets. The role of rheology on misting was also investigated using shear and extensional data. Results show that misting, mainly generated by film splitting, is reduced when the extensional viscosity of the color is larger.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

Similar content being viewed by others

Abbreviations

Ca:

Capillary number

d :

Diameter m

E :

Young modulus MPa

Es:

Elasticity number

Eu:

Euler number

G ′:

Storage modulus Pa

G′′:

Loss modulus Pa

H :

Nip gap μm

k s :

Metzner–Otto constant

L :

Elastomer cover thickness m

m :

Consistency index Pa sn

M w :

Molecular weight g/mol

n :

Flow behavior index

P :

Pressure Pa

Q :

Flow rate m3/s

R :

Roll radius m

Re:

Reynolds number

Tr:

Trouton ratio

U :

Roll speed m/min

V :

Velocity m/s

W :

Applied load kN/m

γ:

Strain

\(\dot \gamma\) :

Shear rate s−1

\({\bar {\dot {\gamma}}}\) :

Effective strain rate s−1

δ:

Nip length μm

Δ:

Difference

\(\dot \varepsilon\) :

Extensional rate s−1

η:

Viscosity Pa s

λ:

Characteristic elastic time s

ρ:

Density kg/m3

σ:

Surface tension mN/m

ϕ:

Volume fraction %

C:

Critical

Corr:

Corrected

E:

Extensional

Exp:

Experimental

R:

Roll

s:

Shear

∞:

Infinite

O:

Orifice

CFD:

Computational fluid dynamics

CMC:

Carboxymethyl cellulose

f.s.:

Full scale

P&J:

Pusey and Jones hardness scale

PEG:

Polyethylene glycol

rpm:

Revolutions per minute

wt:

Weight

References

  • Ascanio G, Carreau PJ, Brito-De La Fuente E, Tanguy PA (2002a) Orifice flowmeter for measuring extensional rheological properties. Can J Chem Eng 80(6):1189–1196

    Google Scholar 

  • Ascanio G, Réglat O, Carreau PJ, Brito-De La Fuente E, Tanguy PA (2002b) High-speed imaging of deformable roll coating flows. In: Proceedings of 11th International Coating Science and Technology, Minneapolis, pp 44–48

  • Ascanio G, Carreau PJ, Réglat O, Tanguy PA (2005) extensional rheology of coating suspensions in relation with misting in film coaters. Nord Pulp Pap Res J 20(1):48–53

    Article  Google Scholar 

  • Carreau PJ, Lavoie PA (1993) Rheology of coating colors: a rheologist point of view. Proceedings of Tappi Advanced Coating Fundamentals, USA, pp 1–9

  • Carreau PJ, De Kee DCR, Chhabra RP (1997) Rheology of polymeric systems: principles and applications. Hanser Publishers, New York

  • Carvalho MS (1996) Roll coating flows in rigid and deformable gaps. PhD Thesis, University of Minnesota

  • Carvalho MS, Scriven LE (1994) Effect of deformable roll cover on roll coating. Tappi J 77:201

    Google Scholar 

  • Carvalho MS, Scriven LE (1997) Deformable roll coating flows: steady state perturbations analysis. J Fluid Mech 339:143

    Article  MathSciNet  MATH  Google Scholar 

  • Cohu O, Magnin A (1997) Forward roll coating of Newtonian fluids with deformable rolls: an experimental investigation. Chem Eng Sci 52:1339

    Article  Google Scholar 

  • Coyle DJ (1984) The fluid mechanics of roll coating: steady flows, stability, and rheology. PhD Thesis, University of Minnesota

  • Coyle DJ (1988) Forward roll coating with deformable rolls: a simple one-dimensional elastohydrodynamic model. Chem Eng Sci 43:2673

    Article  Google Scholar 

  • Coyle DJ, Macosko CW, Scriven LE (1987) Film-splitting flows of shear-thinning liquids in forward roll coating. AIChE J 33:741

    Article  Google Scholar 

  • Della Valle D, Tanguy PA, Carreau PJ (2000) Characterization of the extensional properties of complex fluids using an orifice flowmeter. J Non Newtonian Fluid Mech 94:350

    Article  Google Scholar 

  • Fadat G, Rigdahl M (1987) Viscoelastic properties of CMC/latex coating colors. Nordic Pulp Pap Res J 1:30

    Article  Google Scholar 

  • Grön J, Sunde H, Nikula E (1998) Runnability aspects in high-speed film transfer coating. Tappi J 81:157

    Google Scholar 

  • Kokko A (2001) Evaluation of viscosity, elongational viscosity and dewatering of coating colours at high shear rates. PhD Thesis, Faculty of Chemical Engineering, Å bo Akademi University

  • Lavoie P-A, Carreau PJ, Ghosh T (1997) Rheology of suspensions: The flow behaviour of coating colours. J Pulp Pap Sci 23:J543

    Google Scholar 

  • MacPhee J (1997a) A unified view of the film splitting process (part I). Am Ink Maker 75:44

    Google Scholar 

  • MacPhee J (1997b) A unified view of the film splitting process (part II). Am Ink Maker 75:51

    Google Scholar 

  • Metzner AB, Otto RE (1957) Agitation of non-newtonian fluids. AIChE J 3:3

    Article  Google Scholar 

  • O’Brien VT, MacKay ME (2002) Shear and elongation flow properties of kaolin suspensions. J Rheol 46:557

    Article  Google Scholar 

  • Owens MS, Macosko CW, Scriven LE (2002) Misting in forward roll coating. Proceedings of 11th International Coating Science and Technology, p 52

  • Page A, Carreau PJ, Moan M, Heuzey MC (2002) Rheological behavior of coating colors: influence of thickener and pigment. Can J Chem Eng 80:1181

    Google Scholar 

  • Réglat O, Tanguy PA (1997) Experimental study of the flow in the metering nip of a metering-size press. AIChE J 43:2911

    Article  Google Scholar 

  • Roper III JA, Bousfield DW, Urscheler R, Salminen P (1997) Observations and proposed mechanisms of misting on high-speed metered size press coaters. Proceedings of Tappi Coating Conference, USA, p 1

  • Roper III JA, Salminen P, Urscheler R, Moore E (1998b) Optimization of formulation parameters to reduce misting and orange peel formation on metered film coaters. Proceedings of Tappi Coating Conference, USA, p 37

  • Roper III JA, Salminen P, Urscheler R, Bousfield DW (1998a) Studies of orange peel formation in high-speed film coating. Tappi J 82:231

    Google Scholar 

  • Tiu C, Wang L, Liu T-J (1999) Non-Newtonian effects on pre-metered reverse roll coating. J Non Newtonian Fluid Mech 87:247

    Article  MATH  Google Scholar 

  • Triantafillopoulos NG, Smith MK (1998) Troubleshooting rheology problems in metered size press. Proceedings of Tappi Metered Size Press Forum, p 13

  • Vinjamur M, Scriven LE (2002) Film-split instabilities and patterns in forward roll coating. Proceedings of 11th Int Coating Science and Technology, Minneapolis, MN, p 52

  • Young AE (1997) A theoretical and experimental investigation of deformable roll coating. PhD Thesis, The University of Leeds

  • Yziquel F, Moan M, Carreau PJ, Tanguy PA (1999) Nonlinear viscoelastic behavior of paper coating colors. Nordic Pulp Pap Res J 14:37

    Article  Google Scholar 

Download references

Acknowledgements

The financial support of NSERC is gratefully acknowledged. Thanks are also directed to DGAPA (National University of Mexico) for the financial support.

Author information

Authors and Affiliations

  1. Center of Applied Sciences and Technological Development (CCADET), National University of Mexico, Circuito Exterior, Cd. Universitaria, A.P. 70–186,  , 04510, DF, Mexico

    G. Ascanio

  2. Center for Applied Research on Polymers and Composites (CREPEC), Department of Chemical Engineering, Ecole Polytechnique, Montreal, QC, H3C 3A7, Canada

    P. J. Carreau

  3. Department of Chemical Engineering, Research Unit on Industrial Flow Processes (URPEI), Ecole Polytechnique, Montreal, QC, H3C 3A7, Canada

    P. A. Tanguy

Authors
  1. G. Ascanio
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. P. J. Carreau
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. P. A. Tanguy
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to G. Ascanio.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Ascanio, G., Carreau, P.J. & Tanguy, P.A. High-speed roll coating with complex rheology fluids. Exp Fluids 40, 1–14 (2006). https://doi.org/10.1007/s00348-005-0025-5

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00348-005-0025-5

Keywords

Search

Navigation