Method and apparatus for making a multilayer coating

1 . A method for manufacturing a coated paper grade having at least one side coated with at least two coat layers, the method comprising the steps of

applying a coating furnish layer to at least one surface of said paper web,

drying the coating furnish layer to a point allowing a next coating layer to be applied thereon,

applying a second coating layer on said first coating layer,

drying said second coating layer, and

continuing the application of successive coating layers until the desired coat thickness is attained,

characterized in that

said coating layers are applied using a metering film transfer method operating without leveling of the applied coating layer by doctoring, and

using in at least one of said coating layers a furnish having a solids content of not less than 62%.

2 . The method of claim 1 , characterized in that the solids content of the web treatment agent used in the application of said first coating layer is not less than 65%.

3 . The method of claim 1 or 2 , characterized in that the solids content of web treatment agent furnishes applied in said successive coating layers is reduced stepwise toward the top layer of the finished product.

4 . The method of claim 1 , characterized in that the composition of both the base sheet and the web treatment agents to be applied thereon as separate coating layers is selected such that the pore size in each successive coating layer is smaller than in the underlying layer thereof, whereby the pore size in the underlying layer is adjusted such that the solids particles of the next overlying layer will not penetrate into the underlying layer.

5 . The method of claim 1 or 4 , characterized in that the base sheet is calendered at least once prior to the application of the first coating layer.

6 . The method of any one of foregoing claims, characterized in that the coated paper web is calendered by means of a multinip calender after the application of the last coating layer.

7 . The method of any one of foregoing claims 1 - 5 , characterized in that the coated paper web is calendered by means of a soft-nip calender after the application of the last coating layer.

8 . The method of claim 1 or 2 , characterized in that the coat weight (g/m 2 ) of an underlying coating layer in the dried coat is always higher than the coat weight of the next overlying coating layer.

9 . The method of claim 1 or 2 , characterized in that the ash content of the base sheet is not smaller than 10%.

10 . The method of claim 1 , characterized in that, in the first coating layer applied to the surface of the base sheet, the solids content is at least 66% to 68% at a web speed of 2000 m/min, 68% to 70% at a web speed of 2500 m/min and not smaller than 70% at a web speed of 3000 m/min.

11 . The method of any one of foregoing claims, characterized in that both sides of the paper web are coated simultaneously in each of said application steps.

12 . An assembly for manufacturing a coated paper grade having at least one side coated with at least two coat layers, the assembly comprising

a calender ( 2 ),

at least two coater stations ( 3 , 10 ) for applying at least two coating layers to at least one surface of a base sheet ( 1 ), and

means ( 6 , 7 , 8 , 9 ) for drying each applied coating layer at least partially prior the next treatment step of the web ( 1 ),

characterized in that

said coater stations ( 3 , 10 ) are premetering two-side film transfer applicators comprising two nip-forming film transfer rolls ( 4 ), from the surface of which the coating is transferred simultaneously to both sides of the through-passing base paper web.

13 . The assembly of claim 12 , characterized in that the number of coater stations is two.

14 . The assembly of claim 12 , characterized in that the number of coater stations is three.

15 . The assembly of any one of claims 12 - 14 , characterized in by a multinip calender ( 11 ) adapted to operate in the web travel direction downstream from the last coater station.