On air entrainment in coatings.

A series of experiments that clarify how air bubbles become entrained into coatings are described. The contact line dynamics at the air-liquid interface surrounding a fiber is characterized for a typical coating die operating under atmospheric and pressurized conditions. Glycerin and other viscous liquids are used to reveal that a critical fiber speed exists at which air entrainment begins. The observations confirm that the critical capillary number Ca(c) depends on the physical properties of the coating material, in the form of the Morton number. When the liquid supply is pressurized, the experiments show that adjusting the pressure can stabilize the displaced free surface interface at a prescribed location. Controlling the meniscus location in this way eliminates air entrainment. The threshold occurs when the applied pressure balances the shear exerted on the coating by the moving fiber. Using this approach it is possible to eliminate air entrainment and attain stable wetting at very large values of the capillary number, e.g., Ca congruent with 50.