Skip to main content
SpringerLink
Log in

Visualization study of liquid surface stability for full reverse 3-roll coater with rigid gravure roll

  • Published:
Journal of Coatings Technology and Research Aims and scope Submit manuscript

Abstract

Roll coating systems are widely used to coat a thin liquid layer on a moving substrate, and many publications discussing forward roll coating systems and reverse gap control coating systems are available. Recently, thinner and more uniform layers are required for use with the high-performance solutions involved. Moreover, high line speed coating is also required in order to reduce manufacturing costs. A reverse gravure roll system can coat a thin layer film at high line speed more easily than a flat roll coating system because only the liquid that enters the gravure cell is transferred to the next roll or substrate. However, the existence of the gravure cell complicates the flow between the rolls. To our knowledge, no systematic study in the literature has explored this condition in depth. In the present study, the flow between a reverse deformable roll and a solid stainless steel gravure roll is visualized in order to determine how the uniformity of coating in the high roll speed region is affected by operating parameters, that is, the speed ratio between the rolls and the properties of the coating liquid. The range for coating uniformity is compared with the case of a gap control system. The results show that the stable region can be extended by using the reverse gravure roll system.

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

References

  1. Benkreira, H, Edwards, MF, Wilkinson, WL, “Ribbing Instability in the Roll Coating of Newtonian Fluids.” Plast. Rubber Proc. Appl., 2 137–144 (1982)

    Google Scholar 

  2. Ruschak, KJ, “Boundary Conditions at a Liquid/Air Interface in Lubrication Flows.” J. Fluid Mech., 119 107–120 (1982)

    Article  Google Scholar 

  3. Ruschak, KJ, “Coating Flows.” Ann. Rev. Fluid Mech., 17 65–89 (1985)

    Article  Google Scholar 

  4. Coyle, DJ, “Roll Coating Flows 2: The Ribbing Instability.” Ind. Coat. Res., 2 33–45 (1992)

    Google Scholar 

  5. Carvalho, MS, Scriven, LE, “Deformable Roll Coating Flows: Steady State and Linear Perturbation Analysis.” J. Fluid Mech., 339 143–172 (1997)

    Article  Google Scholar 

  6. Coyle, DJ, Macosko, CW, Scriven, LE, “The Fluid Dynamics of Reverse Roll Coating.” AIChE J., 36 (2) 161–174 (1990)

    Article  Google Scholar 

  7. Hanumanthu, R, Scriven, LE, “Coating with Patterned Rolls and Rods.” Tappi J., 79 126–138 (1996)

    Google Scholar 

  8. Pulkrabek, WW, Munter, JD, “Knurl Roll Design for Stable Rotogravure Coating.” Chem. Eng. Sci., 38 (8) 1309–1314 (1983)

    Article  Google Scholar 

  9. Hoda, N, Kumar, S, “Boundary Integral Simulations of Liquid Emptying from a Model Gravure Cell.” Phys. Fluid, 20 092106 (2008)

    Article  Google Scholar 

  10. Dodds, S, Carvalho, MS, Kumar, S, “The Dynamics of Three-Dimensional Liquid Bridges with Pinned and Moving Contact Lines.” J. Fluid Mech., 707 521–540 (2012)

    Article  Google Scholar 

  11. Yin, X, Kumar, S, “Flow Visualization of the Liquid-Emptying Process in Scaled-up Gravure Grooves and Cells.” Chem. Eng. Sci., 61 1146–1156 (2006)

    Article  Google Scholar 

  12. Savage, MD, “Meniscus Instability and Ribbing.” Ind. Coat. Res., 2 47–58 (1992)

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Rolling and Processing Research Department, Steel Research Laboratory, JFE Steel Corporation, 1 Mizushima Kawasaki-dori, Kurashiki-shi, Okayama, 712-8511, Japan

    Hirokazu Kobayashi

  2. Rolling and Processing Research Department, Steel Research Laboratory, JFE Steel Corporation, 1 Kokancho, Fukuyama, Hiroshima, 721-8510, Japan

    Masato Sasaki

Authors
  1. Hirokazu Kobayashi
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Masato Sasaki
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Hirokazu Kobayashi.

Additional information

This paper was presented at the 16th International Coating Science and Technology Symposium, September 9–12, 2012, in Atlanta, GA (USA).

Rights and permissions

Reprints and permissions

About this article

Cite this article

Kobayashi, H., Sasaki, M. Visualization study of liquid surface stability for full reverse 3-roll coater with rigid gravure roll. J Coat Technol Res 11, 39–46 (2014). https://doi.org/10.1007/s11998-013-9500-8

Download citation

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11998-013-9500-8

Keywords

Search

Navigation