Pre-metering rod

A method of forming a coated paper web comprising the steps of:

• applying a layer of liquid coating from a pan to a first surface of a moving paper web, the motion of the web defining a machine direction of motion;
• removing a portion of the layer of liquid with a rotating rod having a circumference, and having a diameter of between about 1/4 and about three inches, by wrapping the web around the rod circumference between about three degrees and about forty degrees, so that the first surface of the web engages the rod, and having no opposing backing roll engaging a second surface of the web to form a nip with the rod, the rod being driven by a motor connected in driving relation to the rod, the motor driving the rod to rotate in a direction contrary to the direction of motion of the paper web at a rotation rate of 10 to 500 rotations per minute;
• draining excess liquid coating removed from the web first surface by the rod into a catch pan;
• causing the web to wrap around a backing roll so the first side is outermost;
• and
• directing a stream of air from an air knife onto the web first side while the web is supported on the backing roll, the stream of air smoothing the liquid coating on the web first side.

A coater comprising:

• a means for applying a liquid coating to a first surface of a moving paper web;
• a liquid coating pan for supplying the means for applying a liquid coating;
• a rod spaced in a down machine direction from the means for applying a liquid coating, the rod having a diameter between about 1/4 and about 3 inches, the rod defining a circumference, the rod extending in a cross machine direction and engaging the web first surface so that between three degrees and forty degrees of the rod circumference is wrapped by the web, and wherein no other roll engages the web immediately adjacent to the rod;
• a holder supporting the rod in the cross machine direction;
• a liquid coating catch pan for receiving liquid excess coating removed from the web first surface by the rod;
• means for rotating the rod at a rate of between 10 to 500 rotations per minute;
• a backing roll positioned downstream of the rod, and not engaging the rod, the web wrapping around the backing roll so the first surface is facing away from the roll;
• and
• an air knife directed at the web as it passes over the backing roll so smoothing the liquid coating on the first surface of the web.