초록 ▼

An improved film coater which utilizes one or more coater or applicators to transfer coating to the outer surfaces of at least one more rolls, which in turn transfers the coating from the roll surface to one or more sides of the web for coating paper is disclosed. The coater or applicator includes a

An improved film coater which utilizes one or more coater or applicators to transfer coating to the outer surfaces of at least one more rolls, which in turn transfers the coating from the roll surface to one or more sides of the web for coating paper is disclosed. The coater or applicator includes a smoothing doctor on the web and downstream of the one or more rolls, and may also utilize humidity from one of steam showers or a humidity enclosure to assist smoothing. The web may run in any direction, but preferably runs upwardly from the roll toward the doctor to reduce “film split” droplets effect. The present invention also reduces the fiber rise and arrange peel pattern on the coated web, resulting in a smooth uniform coated paper.

대표청구항 ▼

1. A process of coating a paper web on both its sides with a film coater having two applicators, a pair of rolls for coating the paper web, the two applicators applying coatings to the surfaces of the pair of rolls, the process comprising the steps of forming a nip with the pair of rolls, applying c

1. A process of coating a paper web on both its sides with a film coater having two applicators, a pair of rolls for coating the paper web, the two applicators applying coatings to the surfaces of the pair of rolls, the process comprising the steps of forming a nip with the pair of rolls, applying coating to each of the two rolls with the two applicators, running a web through the nip in an upward direction, transferring coatings from the roll surfaces to each of the sides of the web at the nip, separating the web from the rolls and creating film split droplets or mist, causing said film split droplets or mist to fall back onto the roll surfaces, locating two doctors above the nip for leveling coatings on both sides of the web, and leveling and smoothing the coating on both sides of the web with said two doctors for minimizing any residual film split pattern and fiber rise, whereby the web can be coated on both sides and the film split droplets falling back onto the rolls.2. A process as in claim 1, including the further step of showering both sides of said web after leaving the nip.3. A process as in claim 2, including showering both sides of the web before leveling and smoothing both sides of the web.4. A process as in claim 2, including showering both sides of the web after leveling and smoothing both sides of the web to minimize film split caused by the web leaving the two smoothing doctors.5. A process as in claim 2, including showering both sides of the web both before and after leveling and smoothing both sides of the web.6. A process as in claim 2, wherein showering comprises steam showering.7. A process as in claim 2, wherein showering comprises water mist showering.8. A process as in claim 2, wherein showering comprises steam and water mist showering.9. A process as in claim 2, wherein said applying coatings to the two roll surfaces occurs in a III or IV quadrant of said two rolls, and leveling and smoothing one side of the web occurs before leveling and smoothing the other side of the web.10. A process as in claim 9, including the step of showering the two sides of the web before leveling and smoothing.11. A process as in claim 9, including the step of showering the two sides of the web after leveling and smoothing.12. A process as in claim 1, including the step of enclosing both sides of the web during smoothing in a humid atmosphere, wherein said enclosing step starts after the web leaves the nip and ends after the leveling and smoothing.13. A process as in claim 12, comprising the step of showering the web after the nip to provide said humid atmosphere in the enclosure.14. A process as in claim 12, comprising the step of steaming the web after the nip to provide said humid atmosphere in the enclosure.15. A process of coating both sides of a paper web with a film coater having two applicators, a pair of rolls for coating the paper web, the two applicators applying coating to the surfaces of the pair of rolls, the process comprising the steps of forming a nip with the pair of rolls, applying coating to the rolls with the two applicators, running a web through the nip in an upward direction, transferring coating from the roll surfaces to both sides of the web at the nip, separating the web from the rolls and creating film split droplets or mist, causing said film split droplets or mist to fall back onto the roll surfaces locating doctors one on each side of the web above the nip for leveling coatings on each side of the web, and leveling and smoothing the coating on each side of the web with the two doctors for minimizing any residual film split pattern and fiber rise, said applying coating to the roll surfaces occurring in a III or IV quadrant of said rolls, whereby the web can be coated and the film split droplets falling back onto the rolls.16. A process of coating both sides of a paper web with a film coater having two applicators, a pair of rolls for coating the paper web, the two applicators applying coating to the surfaces of the pair of rolls, the process comprising the steps of forming a nip with the pair of rolls, applying coating to the rolls with the two applicators, running a web through the nip in an upward direction, transferring coating from the roll surfaces to both sides of the web at the nip, separating the web from the rolls and creating film split droplets or mist, causing said film split droplets or mist to fall back onto the roll surfaces, locating doctors one on each side of the web above the nip for leveling coatings on each side of the web, and leveling and smoothing the coating on each side of the web with the two doctors for minimizing any residual film split pattern and fiber rise, said leveling and smoothing of one side of the web occurring before leveling and smoothing of the other side of the web, whereby the web can be coated and the film split droplets falling back onto the rolls.17. A process of coating a paper web with a film coater having one or more applicators, a pair of rolls for coating the paper web, the one or more applicators applying coating to at least the surface of one roll of the pair of rolls, the process comprising the steps of forming a nip with the pair of rolls, applying coating to at least one of the rolls with the one or more applicators, running a web through the nip, transferring coating form the roll surface to an adjacent side of the web at the nip, separating the web from the roll and creating film split droplets or mist, causing the film split droplets or mist to fall back, enclosing the web after it leaves the nip in a separate enclosure, providing a humid atmosphere in said separate enclosure, locating one or more doctors after the nip and within the separate enclosure and humid atmosphere for leveling coating on the web, and leveling and smoothing the coating on the web while in the separate enclosure and humid atmosphere with the one or more doctors in the separate enclosure for minimizing any residual film split pattern and fiber rise, and exiting the coated leveled web from the separate enclosure and humid atmosphere, whereby the web can be coated and then leveled and smoothed in a separate enclosure in a humid atmosphere.18. A process as in claim 17, including the further step of showering said web after leaving the nip.19. A process as in claim 18, including showering the web before leveling and smoothing.20. A process as in claim 18, including showering the web after leveling and smoothing to minimize film split caused by the web leaving the smoothing device.21. Process as in claim 17, including providing steam to said enclosure.22. A process as in claim 17, including providing water vapor to said enclosure.23. A process as in claim 17, including the step of running the web through the nip in an upward direction.24. A process as in claim 17, including the step of running the web through the nip in other than an upward direction.