Abstract: 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.

Abstract: An fountain applicator for applying coating liquid onto a web of paper carried past the applicator, has a coating liquid flow path that includes a curved surface along which a sheet of the coating liquid is flowed to subject the sheet to centrifugal force to cause air entrained in the coating liquid to move away from one side of the sheet that is toward the curved surface, so that the one side is relatively free of entrained air. After being flowed along the curved surface, the sheet of coating liquid is directed toward the web in a free standing jet curtain of coating liquid, to contact the web surface primarily with the one relatively air-free side of the coating liquid sheet to decrease the occurrence of skip coating on the web surface, especially when the web is traveling past the applicator at high speeds. The coating is applied in excess onto the web surface and is metered and leveled to a desired coat weight by a downstream doctor.

Abstract: An fountain applicator for applying coating liquid onto a web of paper carried past the applicator, has a coating liquid flow path that includes a curved surface along which a sheet of the coating liquid is flowed to subject the sheet to centrifugal force to cause air entrained in the coating liquid to move away from one side of the sheet that is toward the curved surface, so that the one side is relatively free of entrained air. After being flowed along the curved surface, the sheet of coating liquid is directed toward the web in a free standing jet curtain of coating liquid, to contact the web surface primarily with the one relatively air-free side of the coating liquid sheet to decrease the occurrence of skip coating on the web surface, especially when the web is traveling past the applicator at high speeds. The coating is applied in excess onto the web surface and is metered and leveled to a desired coat weight by a downstream doctor.

Abstract: 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.

Abstract: High gloss ink jet recording media are produced without need for calendering or supercalendering. The media are comprised of a substrate, such as paper, an ink carrier vehicle absorptive coating on the substrate and an ink-receptive coating overlying the absorptive coating. The absorptive coating is made up in major part of a pigment component that is comprised in major part, i.e., 60-100%, and preferably 100%, of calcined clay. The absorptive coating is applied to the substrate at a thickness sufficient to provide a smooth and level surface. The ink receptive coating is porous and made up of constituents that provide requisite ink holdout and print quality functions and that, when applied to the absorptive coating, also provide a high gloss print surface without calendering or supercalendering. The recording media have exceptionally quick ink drying times and provide excellent high-gloss print quality.

Abstract: 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.

Abstract: A jet type coater with a nozzle orifice is provided with an adjustable, internal filter or screen in the head of the coater. The filter has orifices or slots which are formed by relatively movable members and is adjustable to a size smaller than that of the nozzle orifice, to keep the nozzle orifice unclogged and functioning. The internal filter is also easily clearable on the run without shutdown and cleanable with coating liquid and/or water.

Abstract: A method and apparatus are disclosed for reducing or eliminating the precurl in a web of paper. The apparatus includes a decurler which may operate in conjunction with a lead in roll and a bowed roll. Motions are provided to the lead in roll and decurler so that the wrap of the web on the bowed roll remains essentially unaffected by the movement of the decurler into and out of the web. One of the above apparatus or a lead out roll may be skewed to address uneven cross machine curl profile, while the bowed roll addresses baggyness and the decurler, of course curl.

Abstract: A recording medium particularly suitable for electrophotographic copying is characterized by coated paper that for a given basis weight has proportionally less coating and proportionally more fiber than conventional coated paper made for electrophotographic processes. The base sheet of the coated paper is preferably formed square on a paper machine wet end and has on the order of 40-50% less filler than conventional sheet paper made for electrophotographic processes. After being formed and dried, the base sheet is provided with a top coat weight that is approximately 60% less than the typical coat weight used for conventional paper. The coating is formulated to have sufficient viscosity to stay more on the surface of the base sheet. The coated sheet is calendered to a medium gloss on the order of a 75° TAPPI gloss of about 45, both to preserve a degree of surface roughness to enhance runnability of the paper through an electrophotographic copier and to provide a pleasant and easily readable surface.

Abstract: An fountain applicator for applying coating liquid onto a web of paper carried past the applicator, has a coating liquid flow path that includes a curved surface along which a sheet of the coating liquid is flowed to subject the sheet to centrifugal force to cause air entrained in the coating liquid to move away from one side of the sheet that is toward the curved surface, so that the one side is relatively free of entrained air. After being flowed along the curved surface, the sheet of coating liquid is directed toward the web in a free standing jet curtain of coating liquid, to contact the web surface primarily with the one relatively air-free side of the coating liquid sheet to decrease the occurrence of skip coating on the web surface, especially when the web is traveling past the applicator at high speeds. The coating is applied in excess onto the web surface and is metered and leveled to a desired coat weight by a downstream doctor.

Abstract: An fountain applicator for applying coating liquid onto a web of paper carried past the applicator, has a coating liquid flow path that includes a curved surface along which a sheet of the coating liquid is flowed to subject the sheet to centrifugal force to cause air entrained in the coating liquid to move away from one side of the sheet that is toward the curved surface, so that the one side is relatively free of entrained air. After being flowed along the curved surface, the sheet of coating liquid is directed toward the web in a free standing jet curtain of coating liquid, to contact the web surface primarily with the one relatively air-free side of the coating liquid sheet to decrease the occurrence of skip coating on the web surface, especially when the web is traveling past the applicator at high speeds. The coating is applied in excess onto the web surface and is metered and leveled to a desired coat weight by a downstream doctor.

Abstract: A fountain applicator for applying coating liquid onto a web of paper carried past the applicator, has a coating liquid flow path that includes a curved surface along which a sheet of the coating liquid is flowed to subject the sheet to centrifugal force to cause air entrained in the coating liquid to move away from one side of the sheet that is toward the curved surface, so that the one side is relatively free of entrained air. After being flowed along the curved surface, the sheet of coating liquid is directed toward the web in a free standing jet curtain of coating liquid, to contact the web surface primarily with the one relatively air-free side of the coating liquid sheet to decrease the occurrence of skip coating on the web surface, especially when the web is traveling past the applicator at high speeds. The coating is applied in excess onto the web surface and is metered and leveled to a desired coat weight by a downstream doctor.

Abstract: Ink jet recording media have a substrate coated on one or both sides with two layers of coating material. The first layer is a relatively inexpensive ink vehicle absorptive coating comprised in major part of a pigment component that is comprised in major part of relatively inexpensive but highly absorbent calcined clay. The second layer is an ink receptive coating comprised of relatively expensive constituents providing excellent print qualities. Because the first layer provides the important ink vehicle absorbing function, the ink receptive coating can be applied at much lower coat weights than would otherwise be required. This produces recording media having equal or better print qualities than a heavier single layer of the ink receptive material, and does so at much lower cost. Methods of making and applying coatings having high levels of calcined clay are key factors in producing the media.

Abstract: An aqueous talc slurry that exhibits minimal foaming comprises talc pigment, a carboxymethyl cellulose (CMC) wetting agent having a molecular weight of between 50,000 and 150,000, an ionic polyacrylate dispersing agent, and has a solids content of between 55% and 65%. The slurry has an entrained air content of less than about 1% as measured after at least several minutes of low shear agitation. A method of preparing a talc slurry that exhibits minimal foaming comprises the sequential steps of mixing CMC wetting agent with water, adding an ionic polyacrylate dispersing agent, and dispersing talc to result in a solids content of between 55% and 65%. The resultant slurry has an entrained air content of less than 1% as measured after at least 30 minutes of low shear mixing. An aqueous talc slurry containing a small amount of xanthan gum stabilizing agent is stable for prolonged periods.