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首页> 外文会议>TAPPI Coating and Graphic Arts Conference 2006 >A Study for the Statistical Optimization of a High Speed Curtain Coater
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A Study for the Statistical Optimization of a High Speed Curtain Coater

机译：高速幕式涂布机的统计优化研究

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High-speed curtain coating is an emerging technology trying to gain commercial acceptance by the paper industry as a non-impact coating process. Curtain coating could offer enormous economic and process advantages over conventional coating methods, due to its non-impact and excellent coverage at reduced coat weights. Due to its contour nature, it enables excellent coating coverage, resulting in equal coverage at lower coat weights than needed with contact metering coating methods, i.e., rod and blade. Due to non-impact and non-contact type of coating operation, curtain coating will operate with fewer sheet breaks or the strength requirements of the base sheet can greatly reduced. Being a contour coater, there is no film split patterning, and scratching. This results in the production of a defect-free coated surface. It is a versatile coating process, in that it enables a wide range of coating viscosities and coat weights to be applied with a single coater head. In the current study, process and material parameters were varied through a Taguchi OA (first phase) and D-optimal (second phase) design of experiments (DOE), to stabilize a pilot curtain coater at high speeds. The statistical DOE, enabled us to recognize contribution of variables to the curtain stability and optimized them in a relatively few number of trials. The variables studied were curtain height, steam flow rate of a steam substitution system, measures of coating rheology, surfactant dosage, coat weight, web speed, base sheet roughness and base sheet sizing. Trials were conducted at Mitsubishi Heavy Industry's state of the art coating research center in Hiroshima, Japan. The role of boundary layer air removal system was found to be critical to the stability of the curtain, especially at high speeds. Base sheet roughness, in combination with the parameters of the coating formulation, was found to be very important. Coating coverage improved with the smoothness of the base sheet and excellent coating coverage was possible at low coat weights. Higher curtain height and shear thinning coating rheology was favored for obtaining curtain stability at high speeds. The sizing of the base sheet impacted coverage and curtain stability at high speeds due to its impact on the wettability of the base sheet by the liquid curtain. The role of surfactants, although good theoretical understanding exists, was inconclusive.
机译：高速幕涂是一种新兴技术，试图以无冲击涂层工艺获得造纸行业的商业认可。与传统的涂层方法相比，幕帘涂层具有无冲击性且在降低涂层重量的情况下具有出色的覆盖率，因此可以提供巨大的经济和工艺优势。由于其轮廓性质，它能够实现出色的涂层覆盖率，从而以比接触计量涂覆方法（即杆和刀片）所需的更低的涂层重量实现均等的覆盖率。由于采用非冲击和非接触式的涂层操作，幕涂将以较少的碎纸现象进行操作，或者可以大大降低基片的强度要求。作为轮廓涂布机，没有胶片分裂图案和刮擦。这导致产生无缺陷的涂覆表面。它是一种通用的涂层工艺，因为它可以通过单个涂布机头进行多种涂布粘度和涂布重量的涂布。在当前的研究中，通过Taguchi OA（第一阶段）和D-最优（第二阶段）实验设计（DOE）来改变工艺和材料参数，以稳定高速试验幕涂布机。统计DOE使我们能够识别变量对窗帘稳定性的贡献，并在相对较少的试验中对其进行了优化。所研究的变量是帘幕高度，蒸汽替代系统的蒸汽流速，涂层流变性，表面活性剂用量，涂层重量，幅材速度，基片粗糙度和基片施胶量度。在日本广岛的三菱重工最先进的涂料研究中心进行了试验。发现边界层空气去除系统的作用对于窗帘的稳定性至关重要，特别是在高速下。发现基片的粗糙度与涂料配方的参数结合在一起非常重要。随着基片的光滑度，涂层覆盖率得到改善，并且在低涂层重量下可能具有优异的涂层覆盖率。较高的幕帘高度和剪切稀化涂料的流变性有利于高速获得幕帘稳定性。由于基片的尺寸对液幕对基片的润湿性的影响，因此基片的上浆剂在高速下影响覆盖率和帘稳定性。尽管存在良好的理论理解，但表面活性剂的作用尚无定论。

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