title: Coating process regimes in particulate film production by forced-convection-assisted drag-out.
abstract: Operating conditions for the deposition of monolayer and bilayer particulate coatings from aqueous 20-nm-diameter silica dispersions are identified in the context of a drag-out operation assisted by forced convection. The dry film thickness, uniformity, and morphology are assessed within an operating window parametrized by the capillary number and silica dispersion weight fraction. Three film deposition regimes with respect to the capillary number are observed: convective film deposition at low process rates, film entrainment at moderate process rates, and a thin-film transition regime at intermediate process rates. Locally ordered particulate films of variable layering thickness, including (i) a discontinuous submonolayer or (ii) a mixed submonolayer and monolayer, (iii) a mixed monolayer and bilayer, and (iv) multilayers, are dominant under convective deposition conditions. A map of morphologies is presented within the capillary number-weight fraction operating window, where monolayer and mixed monolayer-bilayer films are demonstrated in the thin-film transition regime at an intermediate dispersion weight fraction. A complementary map of the morphologies formed by the drag-out of 110 nm silica dispersions reveals a broader applicability to this type of operability diagram. These operating maps are constructed using model silica dispersions and are therefore relevant to particulate coatings of other inorganic materials.
authors.affiliation: Department of Chemical Engineering and Materials Science, University of Minnesota, Minneapolis, Minnesota 55455, USA.
authors.forename: Damien D
authors.initials: DD
authors.lastname: Brewer
authors.forename: Takumi
authors.initials: T
authors.lastname: Shibuta
authors.forename: Lorraine
authors.initials: L
authors.lastname: Francis
authors.forename: Satish
authors.initials: S
authors.lastname: Kumar
authors.forename: Michael
authors.initials: M
authors.lastname: Tsapatsis
mesh_terms: D008239:Lysine / Q000737:chemistry*; D009038:Motion; D010316:Particle Size; D012822:Silicon Dioxide / Q000737:chemistry*
chemical_list: D012822:Silicon Dioxide; D008239:Lysine