Chemical Engineering Science, Vol.57, No.15, 3025-3032, 2002
Dynamic wetting in metering and pre-metered forward roll coating
This experimental study of dynamic wetting in metering and pre-metered forward roll coating shows that the dimensionless applicator flow rate lambda(A), is a key parameter as it defines whether dynamic failure occurs by air entrainment (lambda(A) > lambda(A,trans)) or cascade (lambda(A) < lambda(A,trans)). lambda(A,trans) is the flow rate when the regime switches from metering to pre-metered and; A,mm, the minimum flow rate in the pre-metered regime. When Ca was varied in the range 0.2-5, lambda(A,trans) and lambda(A,trans) lambda(A,min) were in the range 1.40-1.29 and 1.18-1.15, respectively. These values compare very well with theoretical predictions. The air-entrainment speeds V-M were found to be similar to the corresponding speeds V-p*, measured in plunging tape flow but the cascade speeds V-M* can be smaller or larger depending on;,A. This led to exploring hydrodynamic assistance and drawing an analogy with curtain coating, which was supported by the data. It was also observed that cascade occurred in the pre-metered regime because the dynamic wetting line X-D, moves near the minimum gap position just as in reverse roll coating. Indeed the cascade speeds conform to correlations developed for reverse roll coating. Finally, the study gives data on X-D, and compares them with theoretical predictions. The agreement in this case is only qualitative and this points to deficiencies in current modelling of the dynamic wetting region.