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Mathematical Analysis of Pseudoplastic Polymers during Reverse Roll-Coating.

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  • 1School of Mathematics & Statistics, Xi'an Jiaotong University, Xi'an 710049, China.

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Summary

This study models non-Newtonian polymer thin film coating between counter-rotating rolls. Material parameters control coating thickness, pressure, and separation force, with velocity ratio shifting the separation point.

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approximate solutionlubrication approximation theory (LAT)non-Newtonian fluidnumeric methodsperturbation techniqueroll-coating analysis

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Area of Science:

  • Fluid dynamics
  • Polymer science
  • Materials engineering

Background:

  • Coating processes are crucial in manufacturing for thin films.
  • Understanding non-Newtonian fluid behavior is essential for process control.
  • Roll coating is a common industrial technique for applying liquid films.

Purpose of the Study:

  • To develop a mathematical model for non-Newtonian polymer thin film coating.
  • To analyze the fluid dynamics in a roll coating gap.
  • To investigate the influence of process parameters on coating characteristics.

Main Methods:

  • Mathematical modeling of thin film coating.
  • Application of lubrication approximation theory (LAT).
  • Perturbation technique for analytical solutions.
  • Numerical computation for engineering parameters.

Main Results:

  • Analytical solutions for velocity, flow rate, and pressure gradient derived.
  • Numerical results for coated web thickness, pressure distribution, separation points, separation force, and power input.
  • Graphical and tabular presentation of results for velocity ratio (k) and Weissenberg number (We).

Conclusions:

  • Material parameters offer control over flow rate, pressure, coating thickness, separation force, and power input.
  • Increasing the velocity ratio (k) shifts the separation point towards the nip region.
  • The model provides insights for optimizing non-Newtonian polymer coating processes.