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    Development of superhydrophobic coating on paperboard surface using the Liquid Flame Spray

    Year: 2010

    Journal: Surface and Coatings Technology, Volume 205, Issue 2, 15 October 2010, Pages 436-445, 20111221

    Authors: H. Teisala a, M. Tuominen a , M. Aromaa b , J.M. Mäkelä b , M. Stepien c , J.J. Saarinen c , M. Toivakka c , J. Kuusipalo a

    Organizations: a Paper Converting and Packaging Technology, Department of Energy and Process Engineering, Tampere University of Technology, P.O. Box 541, FI-33101 Tampere, Finland, b Aerosol Physics Laboratory, Department of Physics, Tampere University of Technology, P.O. Box 692, FI-33101 Tampere, Finland, c Laboratory of Paper Coating and Converting, Center for Functional Materials, Åbo Akademi University, Porthansgatan 3, FI-20500 Åbo/Turku, Finland

    This paper introduces a new method for generating nanoscale coatings in a continuous roll-to-roll process at normal pressure. Nanostructured and transparent coating, based on titanium dioxide nanoparticles, was successfully deposited on-line at atmospheric conditions on pigment coated paperboard using a thermal spray method called the Liquid Flame Spray (LFS). The LFS coating process is described and the influences of process parameters on coating quality are discussed. Nanocoating was investigated by a field emission gun scanning electron microscope (FEG-SEM), an atomic force microscope (AFM), an X-ray photoelectron spectroscopy (XPS) and a water contact angle measurement.

    The highest measured water contact angles on the nanocoated paperboard surface were over 160°. Falling water droplets were able to bounce off the surface, which is illustrated by high speed video system images. Regardless of the high hydrophobicity, the coating showed sticky nature, creating a high adhesion to water droplets immediately as the motion of the droplets stopped. Nanocoating with full coverage of the substrate was produced at line speeds up to 150 m/min. Therefore, the LFS coating has scale up potential to industrial level as an affordable and efficient method for coating large volumes at high line speeds.