19052016 copy 2011 COATEMA Coating Machinery GmbH | wwwcoatemade 119052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 1

Dr Klaus Peter Crone RampD

Slot Die CoatingPrinciple and Application

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

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Basics of slot die coatingWhy at all slot die

Key features bull homogeneous layers (mostly thin)bull dosing system (premetering)bull touchfree (except in impregnation mode)bull closed system (no evaporation of solvents)bull full area non stop coating

(meanwhile even stripe and start-stop coatings)

The slot die is the only system that combines all these features

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Range of coating parameters

Printing Speed (mmin) 01 - gt1000

Ink viscosity (mPa s) 1 - 40000

Layer Thickness (microm) 005 - gt1000

Coating accuracy () lt1 (standard 2-5)

Coating width (m) up to approx 4

Basics of slot die coating

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How does it work

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Dosing pump

from reservoir

substrate

coated layerSlot

Basics of slot die coating

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Slot Die examples

100 mm11 oacuteclock

300 mm9 oacuteclock

300 mm double sided

Basics of slot die coating

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manifold

lips

slot area

standard designBasics of slot die coating

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The shim as spacer determinescoating width and slot width

shim coating width

standard designBasics of slot die coating

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bull Basic material corrosion free hard steelbull Option WC-lips for abrasive liquids

Basics of slot die coatingstandard design with WC-lips

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meniscus is formed between die lips and substrate

adhesive stabilization of meniscus by die lips

very low minimum flow rate possible

range of rheological parameters limited for stability

preferrably for low coating speed

Bead mode

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Operating modes of a slot dieBasics of slot die coating

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

stabilization of meniscusby adhesion to die lips

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Basics of slot die coating

Freely falling liquid curtain

No adhesive stabilization of wetting line by die lips

Curtain width shrinks while falling

Minimum flow rate necessary for stable curtain

Preferrable for high coating speed

Curtain mode

Coating roller

Slot die

Freely falling liquid curtain

Manifold (Distribution chamber)

Coating roller

Operating modes of a slot die

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

free falling curtain with edge holders

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

A YouTube-video shows the curtain coating of wooden plates

Courtesy Italdecor srl

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slot die acts as an impregnator with defined liquid release

sucking strength of web must be smaller than release strength of the slot die

slot die with high retention ability has to be used

preferrably for low porosity nonwovens

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

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Impregnation mode

Basics of slot die coatingOperating modes of a slot die

A heated slot die impregnates a glass fiber textile in contact

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Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

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TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

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current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

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manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

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meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

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technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

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Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

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Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

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Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

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Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

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Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

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Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

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3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

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1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

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Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

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Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

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Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

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Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

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Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

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(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

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- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

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Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

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gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

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gap width adjustmentTypes concepts and innovations

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gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

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COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

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Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

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Basics of slot die coatingWhy at all slot die

Key features bull homogeneous layers (mostly thin)bull dosing system (premetering)bull touchfree (except in impregnation mode)bull closed system (no evaporation of solvents)bull full area non stop coating

(meanwhile even stripe and start-stop coatings)

The slot die is the only system that combines all these features

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Range of coating parameters

Printing Speed (mmin) 01 - gt1000

Ink viscosity (mPa s) 1 - 40000

Layer Thickness (microm) 005 - gt1000

Coating accuracy () lt1 (standard 2-5)

Coating width (m) up to approx 4

Basics of slot die coating

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How does it work

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Dosing pump

from reservoir

substrate

coated layerSlot

Basics of slot die coating

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Slot Die examples

100 mm11 oacuteclock

300 mm9 oacuteclock

300 mm double sided

Basics of slot die coating

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manifold

lips

slot area

standard designBasics of slot die coating

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The shim as spacer determinescoating width and slot width

shim coating width

standard designBasics of slot die coating

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bull Basic material corrosion free hard steelbull Option WC-lips for abrasive liquids

Basics of slot die coatingstandard design with WC-lips

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meniscus is formed between die lips and substrate

adhesive stabilization of meniscus by die lips

very low minimum flow rate possible

range of rheological parameters limited for stability

preferrably for low coating speed

Bead mode

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Operating modes of a slot dieBasics of slot die coating

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

stabilization of meniscusby adhesion to die lips

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Basics of slot die coating

Freely falling liquid curtain

No adhesive stabilization of wetting line by die lips

Curtain width shrinks while falling

Minimum flow rate necessary for stable curtain

Preferrable for high coating speed

Curtain mode

Coating roller

Slot die

Freely falling liquid curtain

Manifold (Distribution chamber)

Coating roller

Operating modes of a slot die

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

free falling curtain with edge holders

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

A YouTube-video shows the curtain coating of wooden plates

Courtesy Italdecor srl

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slot die acts as an impregnator with defined liquid release

sucking strength of web must be smaller than release strength of the slot die

slot die with high retention ability has to be used

preferrably for low porosity nonwovens

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

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Impregnation mode

Basics of slot die coatingOperating modes of a slot die

A heated slot die impregnates a glass fiber textile in contact

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Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

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TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

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manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

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meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

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technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

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Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

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Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

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Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

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Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

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Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

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Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

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3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 3

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 4

Basics of slot die coatingWhy at all slot die

Key features bull homogeneous layers (mostly thin)bull dosing system (premetering)bull touchfree (except in impregnation mode)bull closed system (no evaporation of solvents)bull full area non stop coating

(meanwhile even stripe and start-stop coatings)

The slot die is the only system that combines all these features

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Range of coating parameters

Printing Speed (mmin) 01 - gt1000

Ink viscosity (mPa s) 1 - 40000

Layer Thickness (microm) 005 - gt1000

Coating accuracy () lt1 (standard 2-5)

Coating width (m) up to approx 4

Basics of slot die coating

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How does it work

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Dosing pump

from reservoir

substrate

coated layerSlot

Basics of slot die coating

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Slot Die examples

100 mm11 oacuteclock

300 mm9 oacuteclock

300 mm double sided

Basics of slot die coating

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manifold

lips

slot area

standard designBasics of slot die coating

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The shim as spacer determinescoating width and slot width

shim coating width

standard designBasics of slot die coating

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bull Basic material corrosion free hard steelbull Option WC-lips for abrasive liquids

Basics of slot die coatingstandard design with WC-lips

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meniscus is formed between die lips and substrate

adhesive stabilization of meniscus by die lips

very low minimum flow rate possible

range of rheological parameters limited for stability

preferrably for low coating speed

Bead mode

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Operating modes of a slot dieBasics of slot die coating

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

stabilization of meniscusby adhesion to die lips

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Basics of slot die coating

Freely falling liquid curtain

No adhesive stabilization of wetting line by die lips

Curtain width shrinks while falling

Minimum flow rate necessary for stable curtain

Preferrable for high coating speed

Curtain mode

Coating roller

Slot die

Freely falling liquid curtain

Manifold (Distribution chamber)

Coating roller

Operating modes of a slot die

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

free falling curtain with edge holders

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

A YouTube-video shows the curtain coating of wooden plates

Courtesy Italdecor srl

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slot die acts as an impregnator with defined liquid release

sucking strength of web must be smaller than release strength of the slot die

slot die with high retention ability has to be used

preferrably for low porosity nonwovens

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

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Impregnation mode

Basics of slot die coatingOperating modes of a slot die

A heated slot die impregnates a glass fiber textile in contact

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Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 18

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 19

TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 29

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 35

Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

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Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

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Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

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(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
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• Slot die mathematics
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Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 4

Basics of slot die coatingWhy at all slot die

Key features bull homogeneous layers (mostly thin)bull dosing system (premetering)bull touchfree (except in impregnation mode)bull closed system (no evaporation of solvents)bull full area non stop coating

(meanwhile even stripe and start-stop coatings)

The slot die is the only system that combines all these features

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Range of coating parameters

Printing Speed (mmin) 01 - gt1000

Ink viscosity (mPa s) 1 - 40000

Layer Thickness (microm) 005 - gt1000

Coating accuracy () lt1 (standard 2-5)

Coating width (m) up to approx 4

Basics of slot die coating

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How does it work

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Dosing pump

from reservoir

substrate

coated layerSlot

Basics of slot die coating

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Slot Die examples

100 mm11 oacuteclock

300 mm9 oacuteclock

300 mm double sided

Basics of slot die coating

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manifold

lips

slot area

standard designBasics of slot die coating

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The shim as spacer determinescoating width and slot width

shim coating width

standard designBasics of slot die coating

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bull Basic material corrosion free hard steelbull Option WC-lips for abrasive liquids

Basics of slot die coatingstandard design with WC-lips

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meniscus is formed between die lips and substrate

adhesive stabilization of meniscus by die lips

very low minimum flow rate possible

range of rheological parameters limited for stability

preferrably for low coating speed

Bead mode

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Operating modes of a slot dieBasics of slot die coating

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

stabilization of meniscusby adhesion to die lips

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Basics of slot die coating

Freely falling liquid curtain

No adhesive stabilization of wetting line by die lips

Curtain width shrinks while falling

Minimum flow rate necessary for stable curtain

Preferrable for high coating speed

Curtain mode

Coating roller

Slot die

Freely falling liquid curtain

Manifold (Distribution chamber)

Coating roller

Operating modes of a slot die

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

free falling curtain with edge holders

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

A YouTube-video shows the curtain coating of wooden plates

Courtesy Italdecor srl

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slot die acts as an impregnator with defined liquid release

sucking strength of web must be smaller than release strength of the slot die

slot die with high retention ability has to be used

preferrably for low porosity nonwovens

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

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Impregnation mode

Basics of slot die coatingOperating modes of a slot die

A heated slot die impregnates a glass fiber textile in contact

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Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 18

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 19

TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

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manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

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meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

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technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

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Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

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Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

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Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

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Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

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Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

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Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

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Range of coating parameters

Printing Speed (mmin) 01 - gt1000

Ink viscosity (mPa s) 1 - 40000

Layer Thickness (microm) 005 - gt1000

Coating accuracy () lt1 (standard 2-5)

Coating width (m) up to approx 4

Basics of slot die coating

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How does it work

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Dosing pump

from reservoir

substrate

coated layerSlot

Basics of slot die coating

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Slot Die examples

100 mm11 oacuteclock

300 mm9 oacuteclock

300 mm double sided

Basics of slot die coating

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manifold

lips

slot area

standard designBasics of slot die coating

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The shim as spacer determinescoating width and slot width

shim coating width

standard designBasics of slot die coating

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bull Basic material corrosion free hard steelbull Option WC-lips for abrasive liquids

Basics of slot die coatingstandard design with WC-lips

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meniscus is formed between die lips and substrate

adhesive stabilization of meniscus by die lips

very low minimum flow rate possible

range of rheological parameters limited for stability

preferrably for low coating speed

Bead mode

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Operating modes of a slot dieBasics of slot die coating

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

stabilization of meniscusby adhesion to die lips

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Basics of slot die coating

Freely falling liquid curtain

No adhesive stabilization of wetting line by die lips

Curtain width shrinks while falling

Minimum flow rate necessary for stable curtain

Preferrable for high coating speed

Curtain mode

Coating roller

Slot die

Freely falling liquid curtain

Manifold (Distribution chamber)

Coating roller

Operating modes of a slot die

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

free falling curtain with edge holders

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

A YouTube-video shows the curtain coating of wooden plates

Courtesy Italdecor srl

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slot die acts as an impregnator with defined liquid release

sucking strength of web must be smaller than release strength of the slot die

slot die with high retention ability has to be used

preferrably for low porosity nonwovens

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

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Impregnation mode

Basics of slot die coatingOperating modes of a slot die

A heated slot die impregnates a glass fiber textile in contact

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Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

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TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 35

Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

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Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

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Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

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(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
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• Range of coating parameters
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• contents
• Slot die mathematics
• Slide Number 41
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• contents
• Slide Number 63
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• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

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How does it work

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Dosing pump

from reservoir

substrate

coated layerSlot

Basics of slot die coating

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Slot Die examples

100 mm11 oacuteclock

300 mm9 oacuteclock

300 mm double sided

Basics of slot die coating

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manifold

lips

slot area

standard designBasics of slot die coating

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The shim as spacer determinescoating width and slot width

shim coating width

standard designBasics of slot die coating

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bull Basic material corrosion free hard steelbull Option WC-lips for abrasive liquids

Basics of slot die coatingstandard design with WC-lips

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meniscus is formed between die lips and substrate

adhesive stabilization of meniscus by die lips

very low minimum flow rate possible

range of rheological parameters limited for stability

preferrably for low coating speed

Bead mode

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Operating modes of a slot dieBasics of slot die coating

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

stabilization of meniscusby adhesion to die lips

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Basics of slot die coating

Freely falling liquid curtain

No adhesive stabilization of wetting line by die lips

Curtain width shrinks while falling

Minimum flow rate necessary for stable curtain

Preferrable for high coating speed

Curtain mode

Coating roller

Slot die

Freely falling liquid curtain

Manifold (Distribution chamber)

Coating roller

Operating modes of a slot die

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

free falling curtain with edge holders

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

A YouTube-video shows the curtain coating of wooden plates

Courtesy Italdecor srl

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slot die acts as an impregnator with defined liquid release

sucking strength of web must be smaller than release strength of the slot die

slot die with high retention ability has to be used

preferrably for low porosity nonwovens

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

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Impregnation mode

Basics of slot die coatingOperating modes of a slot die

A heated slot die impregnates a glass fiber textile in contact

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Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

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TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

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manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

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meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

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technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

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Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

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Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

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Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

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Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

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Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

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Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

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3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

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Slot Die examples

100 mm11 oacuteclock

300 mm9 oacuteclock

300 mm double sided

Basics of slot die coating

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manifold

lips

slot area

standard designBasics of slot die coating

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The shim as spacer determinescoating width and slot width

shim coating width

standard designBasics of slot die coating

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bull Basic material corrosion free hard steelbull Option WC-lips for abrasive liquids

Basics of slot die coatingstandard design with WC-lips

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meniscus is formed between die lips and substrate

adhesive stabilization of meniscus by die lips

very low minimum flow rate possible

range of rheological parameters limited for stability

preferrably for low coating speed

Bead mode

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Operating modes of a slot dieBasics of slot die coating

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

stabilization of meniscusby adhesion to die lips

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Basics of slot die coating

Freely falling liquid curtain

No adhesive stabilization of wetting line by die lips

Curtain width shrinks while falling

Minimum flow rate necessary for stable curtain

Preferrable for high coating speed

Curtain mode

Coating roller

Slot die

Freely falling liquid curtain

Manifold (Distribution chamber)

Coating roller

Operating modes of a slot die

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

free falling curtain with edge holders

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

A YouTube-video shows the curtain coating of wooden plates

Courtesy Italdecor srl

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slot die acts as an impregnator with defined liquid release

sucking strength of web must be smaller than release strength of the slot die

slot die with high retention ability has to be used

preferrably for low porosity nonwovens

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

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Impregnation mode

Basics of slot die coatingOperating modes of a slot die

A heated slot die impregnates a glass fiber textile in contact

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Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 19

TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 35

Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

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(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
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• Slide Number 4
• Range of coating parameters
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• contents
• Slot die mathematics
• Slide Number 41
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• contents
• Slide Number 63
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• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

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manifold

lips

slot area

standard designBasics of slot die coating

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The shim as spacer determinescoating width and slot width

shim coating width

standard designBasics of slot die coating

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bull Basic material corrosion free hard steelbull Option WC-lips for abrasive liquids

Basics of slot die coatingstandard design with WC-lips

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meniscus is formed between die lips and substrate

adhesive stabilization of meniscus by die lips

very low minimum flow rate possible

range of rheological parameters limited for stability

preferrably for low coating speed

Bead mode

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Operating modes of a slot dieBasics of slot die coating

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

stabilization of meniscusby adhesion to die lips

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Basics of slot die coating

Freely falling liquid curtain

No adhesive stabilization of wetting line by die lips

Curtain width shrinks while falling

Minimum flow rate necessary for stable curtain

Preferrable for high coating speed

Curtain mode

Coating roller

Slot die

Freely falling liquid curtain

Manifold (Distribution chamber)

Coating roller

Operating modes of a slot die

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

free falling curtain with edge holders

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

A YouTube-video shows the curtain coating of wooden plates

Courtesy Italdecor srl

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slot die acts as an impregnator with defined liquid release

sucking strength of web must be smaller than release strength of the slot die

slot die with high retention ability has to be used

preferrably for low porosity nonwovens

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

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Impregnation mode

Basics of slot die coatingOperating modes of a slot die

A heated slot die impregnates a glass fiber textile in contact

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Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

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TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

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manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

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meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

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technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

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Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

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Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

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Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

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Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

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Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

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Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

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3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

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- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

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Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

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gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

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gap width adjustmentTypes concepts and innovations

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gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

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COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 9

The shim as spacer determinescoating width and slot width

shim coating width

standard designBasics of slot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 10

bull Basic material corrosion free hard steelbull Option WC-lips for abrasive liquids

Basics of slot die coatingstandard design with WC-lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 11

meniscus is formed between die lips and substrate

adhesive stabilization of meniscus by die lips

very low minimum flow rate possible

range of rheological parameters limited for stability

preferrably for low coating speed

Bead mode

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Operating modes of a slot dieBasics of slot die coating

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

stabilization of meniscusby adhesion to die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 12

Basics of slot die coating

Freely falling liquid curtain

No adhesive stabilization of wetting line by die lips

Curtain width shrinks while falling

Minimum flow rate necessary for stable curtain

Preferrable for high coating speed

Curtain mode

Coating roller

Slot die

Freely falling liquid curtain

Manifold (Distribution chamber)

Coating roller

Operating modes of a slot die

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 13

Basics of slot die coatingOperating modes of a slot die

Curtain mode

free falling curtain with edge holders

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

A YouTube-video shows the curtain coating of wooden plates

Courtesy Italdecor srl

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slot die acts as an impregnator with defined liquid release

sucking strength of web must be smaller than release strength of the slot die

slot die with high retention ability has to be used

preferrably for low porosity nonwovens

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

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Impregnation mode

Basics of slot die coatingOperating modes of a slot die

A heated slot die impregnates a glass fiber textile in contact

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Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

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TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

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manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

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meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

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Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

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Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

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Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

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(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
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• Range of coating parameters
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• contents
• Slot die mathematics
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Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 10

bull Basic material corrosion free hard steelbull Option WC-lips for abrasive liquids

Basics of slot die coatingstandard design with WC-lips

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meniscus is formed between die lips and substrate

adhesive stabilization of meniscus by die lips

very low minimum flow rate possible

range of rheological parameters limited for stability

preferrably for low coating speed

Bead mode

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Operating modes of a slot dieBasics of slot die coating

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

stabilization of meniscusby adhesion to die lips

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Basics of slot die coating

Freely falling liquid curtain

No adhesive stabilization of wetting line by die lips

Curtain width shrinks while falling

Minimum flow rate necessary for stable curtain

Preferrable for high coating speed

Curtain mode

Coating roller

Slot die

Freely falling liquid curtain

Manifold (Distribution chamber)

Coating roller

Operating modes of a slot die

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

free falling curtain with edge holders

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

A YouTube-video shows the curtain coating of wooden plates

Courtesy Italdecor srl

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slot die acts as an impregnator with defined liquid release

sucking strength of web must be smaller than release strength of the slot die

slot die with high retention ability has to be used

preferrably for low porosity nonwovens

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

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Impregnation mode

Basics of slot die coatingOperating modes of a slot die

A heated slot die impregnates a glass fiber textile in contact

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Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 18

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 19

TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 24

manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 25

differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 35

Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

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Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

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gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 11

meniscus is formed between die lips and substrate

adhesive stabilization of meniscus by die lips

very low minimum flow rate possible

range of rheological parameters limited for stability

preferrably for low coating speed

Bead mode

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Operating modes of a slot dieBasics of slot die coating

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

stabilization of meniscusby adhesion to die lips

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

stabilization of meniscusby adhesion to die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 12

Basics of slot die coating

Freely falling liquid curtain

No adhesive stabilization of wetting line by die lips

Curtain width shrinks while falling

Minimum flow rate necessary for stable curtain

Preferrable for high coating speed

Curtain mode

Coating roller

Slot die

Freely falling liquid curtain

Manifold (Distribution chamber)

Coating roller

Operating modes of a slot die

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 13

Basics of slot die coatingOperating modes of a slot die

Curtain mode

free falling curtain with edge holders

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 14

Basics of slot die coatingOperating modes of a slot die

Curtain mode

A YouTube-video shows the curtain coating of wooden plates

Courtesy Italdecor srl

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 15

slot die acts as an impregnator with defined liquid release

sucking strength of web must be smaller than release strength of the slot die

slot die with high retention ability has to be used

preferrably for low porosity nonwovens

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 16

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

A heated slot die impregnates a glass fiber textile in contact

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 17

Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 18

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 19

TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 20

The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 21

Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 22

Homogeneous CoatingPractical thickness profile

measured thickness

profile

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 23

bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 25

differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 35

Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
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• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
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• Slide Number 23
• Slide Number 24
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• Slide Number 26
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• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
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• Slide Number 57
• Slide Number 58
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• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

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Basics of slot die coating

Freely falling liquid curtain

No adhesive stabilization of wetting line by die lips

Curtain width shrinks while falling

Minimum flow rate necessary for stable curtain

Preferrable for high coating speed

Curtain mode

Coating roller

Slot die

Freely falling liquid curtain

Manifold (Distribution chamber)

Coating roller

Operating modes of a slot die

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

free falling curtain with edge holders

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

A YouTube-video shows the curtain coating of wooden plates

Courtesy Italdecor srl

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slot die acts as an impregnator with defined liquid release

sucking strength of web must be smaller than release strength of the slot die

slot die with high retention ability has to be used

preferrably for low porosity nonwovens

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

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Impregnation mode

Basics of slot die coatingOperating modes of a slot die

A heated slot die impregnates a glass fiber textile in contact

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Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

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TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

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Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

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(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

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- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

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gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
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• contents
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• contents
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• Slide Number 32
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• Slide Number 35
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• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
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• Slide Number 63
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• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

free falling curtain with edge holders

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Basics of slot die coatingOperating modes of a slot die

Curtain mode

A YouTube-video shows the curtain coating of wooden plates

Courtesy Italdecor srl

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slot die acts as an impregnator with defined liquid release

sucking strength of web must be smaller than release strength of the slot die

slot die with high retention ability has to be used

preferrably for low porosity nonwovens

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

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Impregnation mode

Basics of slot die coatingOperating modes of a slot die

A heated slot die impregnates a glass fiber textile in contact

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Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 18

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 19

TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

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manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

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technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

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Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

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Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 14

Basics of slot die coatingOperating modes of a slot die

Curtain mode

A YouTube-video shows the curtain coating of wooden plates

Courtesy Italdecor srl

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 15

slot die acts as an impregnator with defined liquid release

sucking strength of web must be smaller than release strength of the slot die

slot die with high retention ability has to be used

preferrably for low porosity nonwovens

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

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Impregnation mode

Basics of slot die coatingOperating modes of a slot die

A heated slot die impregnates a glass fiber textile in contact

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Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 18

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 19

TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 21

Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 23

bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 25

differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 26

Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 27

meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 28

bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 29

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 32

ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 35

Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
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• contents
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• contents
• Slot die mathematics
• Slide Number 41
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• contents
• Slide Number 63
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• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 15

slot die acts as an impregnator with defined liquid release

sucking strength of web must be smaller than release strength of the slot die

slot die with high retention ability has to be used

preferrably for low porosity nonwovens

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

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Impregnation mode

Basics of slot die coatingOperating modes of a slot die

A heated slot die impregnates a glass fiber textile in contact

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Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 18

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 19

TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 24

manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 25

differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 27

meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 16

Impregnation mode

Basics of slot die coatingOperating modes of a slot die

A heated slot die impregnates a glass fiber textile in contact

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 17

Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 18

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 19

TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 20

The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 21

Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 22

Homogeneous CoatingPractical thickness profile

measured thickness

profile

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 23

bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 35

Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

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gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
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• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

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Advantages

- completely closed system- no change of solid concen-

tration by evaporation- no hazardous vapors

- premetering systemcoating thickness depends onwidth speed and pump flow only

Vp = v B x

- very low layer thicknesses lt1micrompossible by dilution

Disadvantages

- relatively complex and sensitive- works only with adequate

rheology- has to be treated with care

(cleaning no scratches)

- expensive(depending on complexity)

- inherent limited profilehomogeneity (countermeasures see below)

Pros and cons of slot die coatingBasics of slot die coating

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

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TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

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manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

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Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

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3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

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• Range of coating parameters
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• contents
• Slot die mathematics
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Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 18

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 19

TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

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manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

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meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

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Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

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Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

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Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

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Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

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3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

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TechnologiesHomogeneous coating with slot dies

PET edge

Coating edge

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

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manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

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meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

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Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

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Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

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Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

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(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
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• Slide Number 17
• contents
• Slide Number 19
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• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
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• Slide Number 43
• Slide Number 44
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• Slide Number 46
• Slide Number 47
• Slide Number 48
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• contents
• Slide Number 53
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• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

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The target in thickness profile depends on application Eg window foils target is determined by sensitivity of human eye

- standard optical density for window foils in dark state D = 06 ndash 07 (absorption 75-80)

- in this range the human eye detects density variations ofΔD = 001 ndash 0003

(depending on the regularity of the variations)- density is proportional to layer thickness

I = I0 10-ax D = - log II0 = ax ΔD D = Δx x

target of layer homogeneity 17 ndash 04

Homogeneous CoatingTarget of homogeneity

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

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current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

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manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

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meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

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technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

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Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

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Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

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3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

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Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

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(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
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• Slide Number 17
• contents
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• contents
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• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
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• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
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• Slide Number 43
• Slide Number 44
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• contents
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• contents
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Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

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Condition forgood profileΔp3 laquo Δp1

Homogeneous CoatingWhy should a slot die coat homogeneously

theoretical thickness

profileΔp1

Δp2

Δp3

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Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

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manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

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meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

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technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

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Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

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Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

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Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

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Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

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Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

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3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 22

Homogeneous CoatingPractical thickness profile

measured thickness

profile

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bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

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manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

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meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

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Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

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(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

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- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

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Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

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gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
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• Slide Number 12
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• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 23

bull large manifold long slot area highly parallel lips (standard)

bull coat hanger design- profile is compensated by a tilted manifold- conical manifold cross section to keep flow speed constant

(optional to prevent precipitation)- works perfect for adequate rheology only

bull slot width adjustment- slot width is locally narrowed or widened to adjust

the local flow resistence- slot width can be modified by microns only So despite

adjustability the die has nevertheless to be highly precise and a sufficient manifold volume is necessary(the adjustment is a fine tuning only)

Homogeneous CoatingPrinciples to improve the coating profile

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manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 25

differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 35

Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
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• Range of coating parameters
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• contents
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• contents
• Slot die mathematics
• Slide Number 41
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• contents
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• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 24

manifold smallto minimize deadvolume(optional conicalto preventprecipitation)

tilted manifoldto correct thepressure profile

long slot area

Homogeneous CoatingHigh precision coat hanger slot die

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differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

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Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

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current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

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manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

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meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

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Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

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Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

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Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

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Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

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Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

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Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

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3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

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1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 25

differentialadjustment screws

slot (shim edge)

Homogeneous CoatingSlot die with slot width adjustment

space for bendingthe die lip

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 26

Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 27

meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 28

bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 29

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 31

downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 32

ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 35

Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

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Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

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Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

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(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

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- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

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Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

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gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

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gap width adjustmentTypes concepts and innovations

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gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

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COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
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• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 26

Homogeneous Coatingautomatic slot width and gap width adjustment

computerized adjustment of slot width or gap width

Slot widthfor uniformity

Gap widthfor very small coating windows

can be done pneumatically or motorized

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 35

Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

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meniscuson full width

meniscus onreduced width(limited by shim)

Homogeneous CoatingTypical menisci for homogeneous coating

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bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

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manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

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meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

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Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

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Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

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- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

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Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

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gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

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gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

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COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
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• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
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• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 28

bowlike thickness profileperfect thickness profile

Homogeneous CoatingTypical coating profiles

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

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meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

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Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

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Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

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3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

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1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 29

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 31

downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 32

ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 35

Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 30

current status

full areahomogeneous

requirements are metthickness profile variation of 05

stripes downweb requirements are metgood edge definition

stripes crossweb (intermittent coating)

requirements are partially metedge definition of 05-1 mm

depending on liquid

arbitrary patternsrequirements are not met

concepts for realization existresearch project is going on

Web direction

Structured coatingLevels of complexity

abc

1

2

3

4

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downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

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manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 35

Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

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gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 31

downweb stripes of different width hellip

hellip are made by appropriate shims

Structured coatingLevel 2 downweb stripes

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ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

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Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

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gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

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gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

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COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 32

ProblemStripe widening by capillary forces at the edges of the shim teeth

Structured coatingLevel 2 downweb stripes stripe widening

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

moving substrate or

slot area

shim

100micro typ

manifold manifold

slot area

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 35

Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 33

manifold shim meniscusguide

well defined stripes+ + =

Structured coatingLevel 2 downweb stripessuppression of stripe widening by meniscus guide

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 35

Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

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3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

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1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

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Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

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Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

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Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

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Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

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dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

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(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

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- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

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Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

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gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

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gap width adjustmentTypes concepts and innovations

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gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

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COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 34

meniscus guide

Structured coatingLevel 2 downweb stripes

practical shim and meniscus guide

shim

meniscus guide + shim

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 35

Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 35

Intermittent coating requires sudden start stop of the fluid flow

Different methods are available

Structured coatingLevel 3 crossweb stripes (intermittent coating)

Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
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• Slide Number 17
• contents
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• Slide Number 21
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• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
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• contents
• Slide Number 53
• Slide Number 54
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• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 36

technique effectiveness1 stop the pump very low

gives badly defined edges

2 reverse the pump (suck back) low only slightly better than 1

3 reverse the pump (suck back) + lift the die

fair

4 reverse the pump (suck back)+ lift the die+ suck or blow away the meniscus

quite wellbest achievable edge definition about 05 ndash 1 mm

5 die internal control mechanism (yet confidential)

goal 01 mm

Structured coatingLevel 3 intermittent coating techniques

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
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• contents
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• contents
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• contents
• Slot die mathematics
• Slide Number 41
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• contents
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• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 37

Structured coatingLevel 3 intermittent coating

Two different stripe patterns one on top of the other

Leading edgeBattery paste

Trailing edgeBattery paste

Leading edgeSilicone

Trailing edgeSilicone

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

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(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

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- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

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Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

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gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

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COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 38

Pattern coating requires activecontrol devices within the slot dieto control the flow locally Up to now there are no technicalsolutions available

But there is a unique conceptto realize arbitrary patternsusing an SMSD(scanning micro slot die)

Research is going on Coating roller

Slot die

Meniscus

Manifold (Distribution chamber)

Structured coatingLevel 4 arbitrary patterns

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 39

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

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gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 40

Technologies

Slot die mathematics

vmax = C(d) [ σ h (d-h) + Δp d (η b) ] h(ηb)

D =12 η l Vp

Δp Bradic3Δp =

12 η l Vp

D3 B

dVpdt = B v x

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 41

Any flow of liquids isdescribed by a set ofdifferential equations

int ρ v dA = 0 Continuity equation(conservation of mass)

Navier-Stokes-equations (equations ofmotion for incompressible fluids ρ=const)

Δ = differential operators

partvpartt + (v )v = - p + η Δv + f ρ

To describe the meniscus flowof a slot die means to solvethese differential equationsfor given boundary conditions

Can be done by appropriatecomputer programs

Slot die mathematics

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 42

Slot die mathematics

Simulation of slot die flow

Single layer 120microm thick

Single layer 2cm width 250microm gap

YouTube Videos Flow Science Inc

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

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Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 43

Slot die mathematics

Estimation of practical parameters

For practical applications some important parameters can beestimated by analytical calculations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

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Slot die mathematics

Comparison of theory and praxis

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contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 44

Slot die mathematics

Calculation of coating thickness

dVpdt = B v x

Coating thickness wetCoating speedCoating widthFlow rate of the pump

Coating roller

Distance to substrate

Shim thickness

Contrary to a widespread misunderstanding the wet coatingthickness does not depend on the shim thickness

Shim thickness and distance to substrate only help tostabilize the meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 45

3040

5060

7080

90100

110

10

40

160

400

640

0

1000000

2000000

3000000

4000000

5000000

6000000

7000000

8000000

manifoldpressure

(Pa)

shim thickness (micro)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

Vp = 22 mlminB = 400 mml = 28 mm

Δp =12 η l Vp

D3 B

Calculation of internal pressureSlot die mathematics

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

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(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

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- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

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gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 46

1040

160640

2560

10

30

50

70

90

0

100

200

300

400

500

600

shimthickness

(micro)

viscosity (mPas)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

Δp = 22800 PaB = 400 mml = 28 mm

D =12 η l Vp

Δp Bradic3

Slot die mathematics

Calculation of shim thickness

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Diagramm1

Vp = 22 mlminB = 400 mml = 28 mm

10

40

160

400

640

shim thickness (micro)

manifoldpressure(Pa)

viscosity (mPas)

Slot Die MathematicsManifold Pressure dependent on Shim Thickness and Viscosity

114074074074074

456296296296296

182518518518519

456296296296296

730074074074074

48125

192500

770000

1925000

3080000

24640

98560

394240

985600

1576960

142592592592593

57037037037037

228148148148148

57037037037037

912592592592593

89795918367347

359183673469388

143673469387755

359183673469388

57469387755102

6015625

240625

96250

240625

385000

42249657064472

168998628257888

67599451303155

168998628257888

27039780521262

3080

12320

49280

123200

197120

23140495867769

92561983471074

370247933884298

925619834710744

148099173553719

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

30		30		30		30		30
40		40		40		40		40
50		50		50		50		50
60		60		60		60		60
70		70		70		70		70
80		80		80		80		80
90		90		90		90		90
100		100		100		100		100
110		110		110		110		110

Tabelle1

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Duumlsenberechnung				einzugebende Werte
			Ergebnis				D		η		∆p		B		l		Vp			x
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			y=f(x)
													Parameter z
Duumlseninnenuumlberdruck							30		10		114074		400		28		22
						40		10		48125		400		28		22
						50		10		24640		400		28		22
		Einheit		Zahlenwert				60		10		14259		400		28		22
						70		10		8980		400		28		22
Vp		Pumpleistung		mlmin		22				80		10		6016		400		28		22
η		Viskositaumlt		mPas		48000				90		10		4225		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				100		10		3080		400		28		22
D		Maskendicke Schlitzweite		micro		700				110		10		2314		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400
						30		40		456296		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		43102				40		40		192500		400		28		22
		bar		043				50		40		98560		400		28		22
						60		40		57037		400		28		22
						70		40		35918		400		28		22
Maskendicke							80		40		24063		400		28		22
						90		40		16900		400		28		22
						100		40		12320		400		28		22
		Einheit		Zahlenwert				110		40		9256		400		28		22
Vp		Pumpleistung		mlmin		22				30		160		1825185		400		28		22
η		Viskositaumlt		mPas		13000				40		160		770000		400		28		22
l		Laumlnge der Ablaufflaumlche		mm		28				50		160		394240		400		28		22
∆p		Innenuumlberdruck der Duumlse		Pa		22800				60		160		228148		400		28		22
		bar		023				70		160		143673		400		28		22
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				80		160		96250		400		28		22
						90		160		67599		400		28		22
D		Maskendicke Schlitzweite		micro		560				100		160		49280		400		28		22
						110		160		37025		400		28		22
						30		400		4562963		400		28		22
						40		400		1925000		400		28		22
						50		400		985600		400		28		22
						60		400		570370		400		28		22
						70		400		359184		400		28		22
						80		400		240625		400		28		22
						90		400		168999		400		28		22
						100		400		123200		400		28		22
						110		400		92562		400		28		22
						30		640		7300741		400		28		22
						40		640		3080000		400		28		22
						50		640		1576960		400		28		22
						60		640		912593		400		28		22
						70		640		574694		400		28		22
						80		640		385000		400		28		22
						90		640		270398		400		28		22
						100		640		197120		400		28		22
						110		640		148099		400		28		22

Diagramm2

Δp = 22800 PaB = 400 mml = 28 mm

10

30

50

70

90

viscosity (mPas)

shimthickness(micro)

volume flow (mlmin)

Slot Die MathematicsShim Thickness dependent on Viscosity and Volume Flow

394515795669

568990236783

674612521178

754681567631

820625924509

626254789063

903215700429

1070880625788

1197982314359

1302662455838

994117510958

1433765553015

1699917031909

1901678386052

2067847752757

1578063182675

2275960947131

269845008471

3018726270524

3282503698036

2505019156251

3612862801714

4283522503153

4791929257434

5210649823352

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

10		10		10		10		10
40		40		40		40		40
160		160		160		160		160
640		640		640		640		640
2560		2560		2560		2560		2560

Tabelle2

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

Duumlsenberechnung				einzugebende Werte											x
			Ergebnis				D		η		∆p		B		l		Vp			y=f(x)
						(micro)		(mPas)		(Pa)		(mm)		(mm)		(mlmin)			Parameter z
Duumlseninnenuumlberdruck							39		10		22800		400		28		10
						63		40		22800		400		28		10
						99		160		22800		400		28		10
		Einheit		Zahlenwert				158		640		22800		400		28		10
						251		2560		22800		400		28		10
Vp		Pumpleistung		mlmin		22
η		Viskositaumlt		mPas		48000				57		10		22800		400		28		30
l		Laumlnge der Ablaufflaumlche		mm		28				90		40		22800		400		28		30
D		Maskendicke Schlitzweite		micro		700				143		160		22800		400		28		30
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				228		640		22800		400		28		30
						361		2560		22800		400		28		30
∆p		Innenuumlberdruck der Duumlse		Pa		43102
		bar		043				67		10		22800		400		28		50
						107		40		22800		400		28		50
						170		160		22800		400		28		50
Maskendicke							270		640		22800		400		28		50
						428		2560		22800		400		28		50
		Einheit		Zahlenwert				75		10		22800		400		28		70
						120		40		22800		400		28		70
Vp		Pumpleistung		mlmin		22				190		160		22800		400		28		70
η		Viskositaumlt		mPas		13000				302		640		22800		400		28		70
l		Laumlnge der Ablaufflaumlche		mm		28				479		2560		22800		400		28		70
∆p		Innenuumlberdruck der Duumlse		Pa		22800
		bar		023				82		10		22800		400		28		90
B		Schlitzlaumlnge Beschichtungsbreite		mm		400				130		40		22800		400		28		90
						207		160		22800		400		28		90
D		Maskendicke Schlitzweite		micro		560				328		640		22800		400		28		90
						521		2560		22800		400		28		90

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 47

Force caused by shear This force pulls the meniscus to the right

Shear force in general Fs = η A v d

The shear takes place mainly over the thickness h Fs = η B b v h

A

dv

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Shear force Fs

Slot die mathematics

Calculation of shear force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 48

Force caused by surface tension This force pulls the meniscus to the left

Surface tension σ causes pressure p inside of a fluid sphere p = 2 σ rIn the meniscus the pressure is approximately p = σ (d-h)

The corresponding pressure force is Ft = p A = p B h = σ B h (d-h)

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y surface tension force Ft

Slot die mathematics

Calculation of surface tension force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 49

Force caused by reduced pressure on the rear of the meniscusThis force pulls the meniscus to the left

Fv = p A = Δp B d

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y

vacuum force Fv

reduced pressure Δp

Slot die mathematics

Calculation of vacuum force on meniscus

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 50

Stability of the meniscusThe meniscus is stable as long as the right bound shear force is smaller than the sum of left bound forces At maximum speed the forces are equal

Fs = Fv + Ft vmax = C [ σ h (d-h) + Δp d (η b) ] h(ηb) C(d) = scaling factor

coating thickness h

slot width w

coating gap d

web speed v

lip width b

coating width B

x

y Fs = Fv + Ft

Slot die mathematics

Estimation of coating speed

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 51

Slot die mathematics

Comparison of theory and praxis

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 52

contents

Coatema

Scaling up new technologies

Slot diemathematics

Slot dietypes concepts andinnovations

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 5323102014 1

dynamic wetting line

static wetting linestatic wetting line

optimal static wetting lines

stabilization of wetting lines by undercut lips

Standard die lipsare only weeklypinpointing thestatic wetting lines

Undercut lipsare stronglypinpointing thestatic wetting lines(similar to comma bar)

Types concepts and innovationsModification of die lips

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 54

(p2 - p1) ltlt (p1 - p0) (p2 - p1) ltlt (p1 - p0)

standard delta design for moreuniform pathlengths

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 55

coat hanger design for tiny manifolds

double manifold for 2-fold uniformization

(p1 - p2) + (p2 - p0) = (p1 - p0)

p0

p1p2 p2

p0

p1p2 p2

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 56

- Predistribution by obstacles in the manifold- Reduced flow resistance by low σ coating- Slot area remains uncoated or hard coated

Low σ coating

Uncoatedor hard coated

randomized predistribution stackable version

Alternative designsTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 57

- no precipitation of solids in dispersions by strong current perpendicular to coating flow- the liquid has to be pumped at sufficient pressure level- pressure difference inlet ndash outlet has to be small to fulfill pressure condition

Cross Flow Slot Die

Alternative designs

This system is no longer dosing but pressure controlled Insofar one of the main advantages of slot dies is lost

To achieve constant flow Ioutthe average pressure (p1+ p2)2 has to be controlled as a function of the flow Iout = I1-I2

Iout p0

p1p2

p1 ~ p2 gtgt p0~

I1I2

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 58

Problem poorly soluble solids mayprecipitate at static wettinglines causing particles andstreaks

3-slot-dieAlternative designs

Solution 3-slot-dies coat thinlayers of pure solventon top and beneaththe main layer

Precipitation is prevented

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 59

gap width adjustment

ok

ok

ok

Possible misalignments between slot die and roller

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 60

gap width adjustmentTypes concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 61

gap width adjustment

computerized adjustment of gap width for very narrow coating windows

Types concepts and innovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 62

contents

Coatema

Scaling up new technologies

Slot diemathematics

Summary

Homogeneousslot die coating

Structuredslot die coating

Basics ofslot die coating

Slot dietypes concepts andinnovations

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 63

Summary

Whenever a coating method is said to be working donacutet believe it unless you saw it

Slot dies are versatile precise instruments for manyapplications Nevertheless it is true what a wise man said

slot die coating

So if you donacutet trust the theory book trials in our technical center

Coating is complex If anybody claims tounderstand every detail hellip

hellip for sure he is not an expert

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2016 COATEMA Coating Machinery GmbH | wwwcoatemade 64

COATEMA Coating Machinery GmbHDr Klaus Peter CroneRoseller Str 4D-41539 Dormagen021 33 97 84 ndash 0KCronecoatemadeTHANK

YOU

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65

19052016 copy 2014 COATEMA Coating Machinery GmbH | wwwcoatemade 65

• Slide Number 1
• contents
• contents
• Slide Number 4
• Range of coating parameters
• Slide Number 6
• Slide Number 7
• Slide Number 8
• Slide Number 9
• Slide Number 10
• Slide Number 11
• Slide Number 12
• Slide Number 13
• Slide Number 14
• Slide Number 15
• Slide Number 16
• Slide Number 17
• contents
• Slide Number 19
• Slide Number 20
• Slide Number 21
• Slide Number 22
• Slide Number 23
• Slide Number 24
• Slide Number 25
• Slide Number 26
• Slide Number 27
• Slide Number 28
• contents
• Slide Number 30
• Slide Number 31
• Slide Number 32
• Slide Number 33
• Slide Number 34
• Slide Number 35
• Slide Number 36
• Slide Number 37
• Slide Number 38
• contents
• Slot die mathematics
• Slide Number 41
• Slide Number 42
• Slide Number 43
• Slide Number 44
• Slide Number 45
• Slide Number 46
• Slide Number 47
• Slide Number 48
• Slide Number 49
• Slide Number 50
• Slide Number 51
• contents
• Slide Number 53
• Slide Number 54
• Slide Number 55
• Slide Number 56
• Slide Number 57
• Slide Number 58
• Slide Number 59
• Slide Number 60
• Slide Number 61
• contents
• Slide Number 63
• Slide Number 64
• Slide Number 65