Stability and disturbance of coating films

In the studies of two-roll metering and application systems, two types of disturbances were observed. These were termed “ring type” and “irregular” disturbances. This research established that the physical reason for the appearance of the ring type instability is the competition between surface tension and centrifugal forces at the liquid-air interface. The rings are generated at the surface of the dynamic liquid meniscus, in the gap between the rolls, because of the very large centrifugal forces there. Considering conditions of a constant interfacial pressure difference (pressure jump), one can reduce the problem to one with only one free parameter, viz., the radius of the meniscus, and calculate the wavelength of the disturbances. There is no single formula which will adequately describe the dynamic meniscus. Its curvature depends on the rheological properties of the fluid and on the kinematic conditions in the process. Dimensional analysis is combined with experimental findings to yield a formula for the radius of the meniscus for fluids having a high yield stress for the case of two counter-rotating rolls.The rheological behavior of a flowing starch adhesive in the dynamical meniscus is analyzed. The theoretical and experimental studies show that systems using two counter-rotating rolls practically always produced ring-type instabilities with all types of fluids.The picture is more complex for co-rotating roll systems. When non-Newtonian adhesives are used, ring type disturbances are observed in one zone of roll speed ratios, and irregular disturbances are observed in another zone. The two zones are separated by a speed ratio zone (a “speed window”) where a more or less perfectly stable fluid layer is observed. When Newtonian oils are used, there are two such speed windows. The first one corresponds to very low metering roll speeds and a minimum of liquid transfer to the applicator roll. The second stable zone occurs at high metering roll speeds and yields a maximum of liquid transfer. The physical reason for the high transfer rate in the high speed “window” is considered and shown to be the thin air layer following the surface of the metering roll. The air pumped into the metering gap returns along the applicator roll and accelerates the film on the applicator roll in the process. Under these conditions the fluid-air interface may become unstable, leading to the “irregular” type of disturbance.