slot die coating thickness control

Process-dependent conductivity and film homogeneity of slot-die-coated PEDOT:PSS–PVA composite films | Journal of Coatings Technology and Research
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Response of slot coating flow to gap disturbances: effects of fluid properties, operating conditions, and die configurations | Journal of Coatings Technology and Research
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Process-dependent conductivity and film homogeneity of slot-die-coated PEDOT:PSS–PVA composite films | Journal of Coatings Technology and Research

In this study, we investigate the impact of process parameters on homogeneity and electrical conductivity of slot-die-coated PEDOT:PSS–PVA composite films that are doped with DMSO. Due to a strong correlation between conductivity and morphology of PEDOT:PSS films and the latter’s dependency on the processing step itself, we apply slot die coating for maximized process control and systematically evaluate the impact of coating gap, speed, and film thickness. Since the entire coating and drying process is run in batch mode, the setup is optimized regarding steady-state conditions and high homogeneity of the films. Overall, for the films manufactured in batch mode, we obtain a reproducibility film thickness of 99% and a low deviation from the set film thickness (below 8%). In order to analyze the impact of the coating parameters, stable operating points derived from the viscocapillary model are chosen and either the dimensionless gap or the capillary number is varied. Coating gap and film thickness emerged as dominating parameters, leading to an increase in conductivity of 40% and 70%, respectively, or, when changing both simultaneously, of 157%. Only a minor impact of shear forces (increase of 10%) was found.

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Response of slot coating flow to gap disturbances: effects of fluid properties, operating conditions, and die configurations | Journal of Coatings Technology and Research

Slot coating is perhaps one of the most successful film manufacturing methods and is used to produce a wide variety of products. It is a pre-metered method and ideal for high-precision coating: the steady-state thickness is precisely controlled by the flow rate fed to the die and the web speed. However, the coating method is surrounded by small-scale disturbances that can destroy film thickness uniformity. Among various disturbances, a periodic change of the coating gap, the so-called gap disturbance, is considered the most dangerous in previous studies, e.g., Romero and Carvalho (Chem Eng Sci 63(8):2161–2173, 2008), Tsuda et al. (AIChE J 56(9):2268–2279, 2010), and Lee and Nam (AIChE J, 2015). However, the effects of fluid properties, operating conditions, and die configurations on the slot coating flow under gap disturbances are not examined in detail. In this study, we revisit the computer-aided analysis of transient slot coating flow designed to predict the thickness variations under gap disturbance. Extensive computational predictions reveal important parameters for suppressing film nonuniformity that can be induced by gap disturbance.