A Method to Produce Paperboard with a Lightweight Low-Density Coating, TAPPICon25

A method and the resulting coated product are described in which a coating layer is produced that consists of a network of bubble-shaped air-filled voids within the coating. This is accomplished by instantaneously flash-drying all the water in the coating as it exits the application nip. The nip is formed between a polished chrome drum and a deformable press roll. The combination of the drum temperature, nip pressure and nip width allow for sufficient energy to be transferred to the coating to completely flash-dry it. The pressure within the nip is sufficient to allow the coating to superheat within the nip, then flash boil as it exits the nip. This boiling and expansion is constrained by the roll surface resulting in a coated surface that mirrors the polished surface. The coating immobilizes while in the process of boiling which preserves the bubble structure. With a coat weight of 5 gsm, a flat, smooth surface is produced. This process was scaled up to production speeds as high as 450 m/min.

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