67
Fundamentals of Slot Coating Process Prof. Marcio Carvalho http://carvalho.usuarios.rdc.puc-rio.br/ [email protected]

Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

  • Upload
    lamliem

  • View
    243

  • Download
    17

Embed Size (px)

Citation preview

Page 1: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Fundamentals of Slot Coating Process

Prof. Marcio Carvalho

http://carvalho.usuarios.rdc.puc-rio.br/

[email protected]

Page 2: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Coating process is the main manufacturing step

for many different (old) products…

Adhesive tapes Magnetic tapes and

disks Paper

Needs:

Higher yields and faster production speed;

Process improvement and optimization.

Introduction

Page 3: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Flexible and transparent

electronics

Thin / flexible displays:

Plasma, LCD, OLED, …

Coating process is the main manufacturing step

for many different (new) products…

Needs:

Uniformity requirements are extremely tight;

May need 3D features;

Process optimization to minimize film thickness variation.

Page 4: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

… and “is the most promising approach to

practical fabrication of nanoparticle structures” ( Fujita & Yamaguchi, 2006)

(Prevo and Velev, 2007)

Needs:

Complex internal microstructure of each layer;

Industrial production speeds (prototype speeds are microns/sec)

Process development.

Page 5: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

FUNCTIONAL COATINGS AND FILMS

Coatings and films produced by depositing a liquid

layer and subsequently solidifying it are vital

ingredients of many different kind of products.

The interior of many coatings and films has to have

particular microstructure or nanostructure in order

to function as intended, whether optically, photo-

chemically, electronically or mechanically.

Page 6: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

SOLUTION FORMULATION

COATING PROCESS CONDITIONS

MICROSTRUCTURE OF COATED LAYER

FINAL PRODUCT PERFORMANCE

Fundamental understanding of all steps of the

product development and manufacturing is

crucial for the product & process optimization

Page 7: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Unit Operations of a typical coating line

Liquid wets the substrate and forms a thin uniform film;

In most cases, the film should be thin and uniform;

Limitations on how fast this process can be run.

Page 8: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Development of Coating Technology

DEVELOPMENTS WERE RESTRICTED TO EACH INDUSTRY SEGMENT

FIRST PART OF 20TH CENTURY, COATING TECHNOLOGY WAS AN ART

COATING IS A MULTI-DISCIPLINARY SUBJECT

WETTING, SPREADING;

ADHESION;

FLUID MECHANICS AND RHEOLOGY;

CHEMISTRY, INTERFACIAL SCIENCE; …

FROM 1940’S, MATHEMATICAL MODELING AND CAREFUL EXPERIMENTS

(NOT ONLY PILOT TRIALS) STARTED TO BE USED

TO DEVELOP AND IMPROVE COATING PROCESSES

COMPETITIVE PRESSURE DRIVES THE TECHNOLOGY,

IMPORTANT TO ANALYZE THE PHYSICAL MECHANISMS THAT

DETERMINES THE SUCCESS OR FAILURE OF THE PROCESS

Page 9: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Technological Challenges in the Coating Industry

Thinner and more uniform wet coating layer;

Reduction of emission of organic solvents –

more concentrated solutions;

New coating liquid formulations and

more complex product structure;

Discrete and non-continuous coating;

Increase in line speed and yields;

Adapting existing coating lines for new products;

Page 10: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Coating Fundamentals Research

Move from not only Know-how (process developement) to also Know-why (process understanding) Need fundamental understanding of the basics mechanisms involved in all phases of the process: liquid preparation, coating, and solidification.

Theory

Numerics Experiments

Need specially developed experimental and numerical tools to be able to study in detail all the mechanisms involved.

Page 11: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Flow and microstructure development visualization

Slot coating visualization: analysis of bead breakup mechanisms – Romero and Carvalho (2004) Micro structure development

During drying – Cardinal and Francis, AIChE J (2011)

Page 12: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Computer-aided theory for flow prediction

Prediction of failure mechanisms and coating window

Roll coating

Slot coating Curtain coating

Tensioned Web coating

Page 13: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Slot Coating Process – Fundamentals

SLOT COATING IS USED IN THE MANUFACTURING PROCESS

OF MANY DIFFERENT PRODUCTS

PRE-METERED METHOD: THICKNESS IS SET BY FLOW RATE

FLOW UNIFORMITY IN THE COATING BEAD IS STRONGLY AFFECTED

BY OPERATING PARAMETERS

Page 14: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

FUNDAMENTAL ASPECTS OF SLOT COATING

OPERATING CONDITIONS

GAP

FLOW RATE (OR FILM THICKNESS)

WEB SPEED

DIE CONFIGURATION (GEOMETRY)

LIQUID PROPERTIES

SUCH THAT, FLOW IS

TWO-DIMENSIONAL

STEADY STATE

STABLE TO SMALL DISTURBANCES

Page 15: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

FORCES ARE THE KEY TO UNDERSTAND FLOW CONDITIONS

TURNING FLOW (2-D FLOW)

ALMOST RECTILILNEAR FLOW (DRAG + PRESSURE GRADIENT)

PRESSURE, VISCOUS, SURFACE TENSION AND INERTIAL FORCES

MUST BALANCE TO PERMIT STEADY, 2-D FLOW

IF FORCES ARE NOT IN BALANCE, COATING BEAD WILL BREAK INTO

A 3-D FLOW (RIVULETS, RIBBING,…) OR TRANSIENT FLOW

CONCEPT OF COATING WINDOW

Example of Flow inside a

slot coating bead

Page 16: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

THE COATING WINDOW IS BORDERED BY DEFECTS

UPSTREAM PRESSURE TOO LOW

LIQUID INVADES VACUUM CHAMBER

PREMETERED ACTION IS LOST

NOT ENOUGH VACUUM

UPSTREAM MENISCUS

INVADES COATING BEAD

MINIMUM WET THICKNESS THAT CAN

BE COATED AT

GIVEN SUBSTRATE SPEED

VCa

Page 17: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

LOW-FLOW LIMIT:

MINIMUM COATING THICKNESS AT A GIVEN SUBSTRATE SPEED ;

MAXIMUM SUBSTRATE SPEED AT A GIVEN COATING THICKNESS .

Low-flow limit

Page 18: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

RIBBING RIVULETS

Page 19: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

V

t

H0

VacVac

Vt

H0

?

t

H 0

COATING WINDOW IN PLANE OF

VACUUM VS THICKNESS

COATING WINDOW IN PLANE OF

WEB SPEED VS THICKNESS

THE FASTER THE WEB SPEED,

THE LARGER IS THE

MINIMUM WET THICKNESS

Page 20: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

COATING BEAD REGION

- FRONTAL VIEW

VISUALIZING THE DIFFERENT MECHANISMS OF BEAD BREAKUP Romero, Scriven and Carvalho (JNNFM, 2004)

Page 21: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

CAMERA

GLASS ROLL

MIRROR

VACUUM BOX

FIBEROPTICS

SIDE PLATE

SLOT DIE 100m

Page 22: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

LOWER PRESSURE — “VACUUM”

ATMOSPHERIC PRESSURE

FLOW VIEWED THROUGH GLASS ROLL

RO

LL

MO

TIO

N

Page 23: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

INVASION OF THE

UPSTREAM MENISCUS

INVASION OF THE

DOWNSTREAM MENISCUS

Page 24: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

(c)

DEFINITIONS OF OPERATING LIMITS

IN SLOT COATING PROCESS

Page 25: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

LUBRICATION APPROXIMATION MODEL – Rectilinear Flow

Q

t = Q / V PU

PE

PD

P0

P1

PC

DH

sH

FLOW IN FEED SLOT S

ECs

L

PPHQ

12

3

FLOW UPSTREAM

UH

2120

3

U

U

EUUU

VH

L

PPHQ

EU PPP 00

Page 26: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Couette Poiseuille

VISCOUS FLOW IN SLOT COATING – CONT.

FLOW DOWNSTREAM

DHPE

PD

P1

t = Q / V D

DEDD

D

D

DED

L

PP

V

HHt

VH

L

PPHVtQ

122

212

3

3

IF 0)(for 2

DDED LPP

Ht

IF 0)(for 2

1 DDED LPPP

Ht

ambamb

DEU

PPPP

PPPPP

01

10

IF

DL

VACUUM IS NEEDED, OTHERWISE FLOW BREAKS INTO RIVULETS

Page 27: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

IMPROVING BEAD STABILITY BY VACUUM APPLICATION

(BEGUIN, 1954, US PATENT 2,681,294)

Page 28: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

FLOW DOWNSTREAM – CONT.

Couette Poiseuille

+ =

Couette Poiseuille

+ =

FLOW IS A COMBINATION OF DRAG (COUETTE) AND

PRESSURE DRIVEN (POISEUILLE)

THE THINNER THE COATING THICKNESS,

THE STRONGER THE POISEUILLE CONTRIBUTION

TH

INN

ER

CO

AT

ING

TH

ICK

NE

SS

IF 3

DHt

RECIRCULATION APPEARS UNDER

DOWNSTREAM DIE LIP

Page 29: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

ULDL

vacP ambP

RELATION BETWEEN

VACUUM AND BEAD LENGTH

D

U

UD

D

Dvacamb H

H

VLt

H

H

VLPPVac

33

6

2

12

THE GREATER THE VACUUM, THE GREATER THE UPSTREAM BEAD LENGTH

IN THE LIMIT OF NO UPSTREAM COATING BEAD

MINIMUM VACUUM NEEDED FOR GIVEN COATING THICKNESS t

THIS REGIME IS UNSTABLE – IMPOSSIBLE TO MAINTAIN AS

STEADY, TWO-DIMENSIONAL FLOW

2-D FLOW BREAKS INTO PARALLEL RIVULETS ON THE WEB

t

H

H

VLPPVac D

D

Dvacamb

2

123min

Page 30: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

THE GREATER THE UPSTREAM BEAD LENGTH, THE GREATER

THE STABILITY AGAINST RIVULET FLOW, AND THE

GREATER THE ABILITY OF THE COATING BEAD TO

ACCOMMODATE FLUCTUATIONS.

CONCERNS WITH RECIRCULATION, IF PRESENT.

COATING DIES HAVE A FIXED UPSTREAM LIP LENGTH

THERE IS A MAXIMUM VACUUM THAT CAN BE APPLIED BEFORE

THE UPSTREAM BEAD BECOMES TOO LONG AND

INVADES THE VACUUM BOX – WEEPING

PREMETERING IS LOST

THE RANGE OF VACUUM OVER WHICH

SLOT COATER CAN BE OPERATED GIVES

DEFINES THE COATING WINDOW

Page 31: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

COATING WINDOW – LOW FLOW LIMIT

BASIC MECHANISM WELL DESCRIBED BY VISCOCAPILLARY MODEL

R

t

H0

V

Q = V t = Qcouette - QPoiseuille

Qcouette = V H0 / 2

Qpoiseuille P2 - P1 = / R

AT A FIXED WEB SPEED, MINIMUM THICKNESS OCCURS WHEN

Qpoiseuille IS MAXIMUM R IS MINIMUM

(1)

(2)

2

0min

tHR

tHPP

0

max12

2

FROM FILM-FLOW EQUATION t

CaPP3/2

12 34.1

AT THE ONSET OF LOW-FLOW LIMIT

2

3

0 1

265.0

tH

VCa

Page 32: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

LUBRICATION MODEL CAN BE USED TO PREDICT THE

RANGE OF OPERABILITY FOR DIFFERENT PARAMETERS

FLOW NEAR DOWNSTREAM FREE SURFACE

Couette Poiseuille

DHPE

PD

P1

t = Q / V

DL

R

t

VPPP DD

32

1 34.1

Landau-Levich eq.

Young-Laplace eq.

RPPP DD

1

(1)

(2)

Geometric relation (meniscus is an arc of circle).

1arccos

R

tHD (3)

Flow under downstream die lip

212

3

D

D

DED VH

L

PPHVtQ

2

123

D

D

DDE

Ht

H

VLPP

(4)

Page 33: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

FLOW NEAR UPSTREAM FREE SURFACE

2)(120

3

U

DCL

EUUU

VH

X

PPHQ

PE

x

PU

Couette Poiseuille

UH

DCLX

UL

VACU PPP 0

Flow under upstream die lip

Neglect capillary effect on upstream meniscus

xDCL is < 0

2

6U

VACEDCL H

V

PPX

(5)

Page 34: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

FAILURE MECHANISMS

VCapillary number

UDCL LX

0DCLX

0(1)

(3)

(2)

Page 35: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Free variable: FILM THICKNESS t

Maximum film thickness

Failure mechanism (3) : Bead invades the vacuum box

2

6

U

UVACE

H

VLPP

UDCL LX

Eq. (5)

Eq. (4)

2

12632

D

D

D

U

UVACD

Ht

H

VL

H

VLPP

Eq. (1) t

VPD

32

34.1

0661

34.112

22

32

3

D

D

U

UVAC

D

D

H

VL

H

VLP

t

Vt

H

VL

MAXt is the root of Eq.(6)

(6)

Page 36: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Minimum film thickness

Failure mechanism (1) : Downstream meniscus invades coating bead

Or

Failure mechanism (2) : Upstream meniscus invades coating bead

Failure mechanism (1)

211

tHR

R

tH DD

Eq. (1)

and (2)

0Eq. (3)

Rt

V

32

34.1

32

32

)1(

34.12

34.1

V

HV

tD

MIN (7)

Page 37: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Failure mechanism (2)

0DCLXEq. (5)

VACE PP

Eq. (4)

and (2)

2

1234.1

3

32

D

D

DVAC

Ht

H

VL

t

VP

061

34.112

2

32

3

VAC

D

D

D

D PH

VL

t

Vt

H

VL

)2(

MINt is the root of Eq.(8)

(8)

)2()1( ,max MINMINMIN ttt

Page 38: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

LOW FLOW LIMIT MAXIMUM WEB SPEED AT A GIVEN FILM THICKNESS

MINIMUM FILM THICKNESS AT A GIVEN WEB SPEED

0.001

0.01

0.1

1

10

0 10 20 30 40 50

Cap

illa

ry N

um

ber

,

V /

Gap / Film Thickness

Stable

Unstable

2

3

0 1

265.0

tH

VCa

THE MAXIMUM POSSIBLE WEB SPEED FALLS AS THE

WET FILM THICKNESS DECREASES

FOR dyn/cm 25 cP; 20 mils; 4 mils; 6.0 0 Ht Vmax = 30 ft/min

VISCOCAPILLARY MODEL VALID ONLY AT LOW CAPILLARY NUMBER

EXPERIMENTS HAVE SHOWN EXAMPLES WHERE THE MODEL

FAILS TO PREDICT THE CORRECT MAXIMUM SPEED

Page 39: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

FINITE ELEMENT MESH

FREE SURFACE

FREE SURFACE

TWO-DIMENSIONAL MODEL – Navier-Stokes equations

Page 40: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

TH

INN

ER

CO

AT

ING

TH

ICK

NE

SS

THICK COATING:

NO RECIRCULATION

RECIRCULATION ATTACHED TO

FREE SURFACE APPEARS

AT

MENISCUS BECOMES MORE

CURVED AS THICKNESS FALLS

3/0 tH

Page 41: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

0.45

0.5

0.55

0.6

0.65

0.7

0 0.02 0.04 0.06 0.08 0.1 0.12

Po

siti

on

alo

ng t

he

web

, X

(mm

)

Position across the bead, Y (mm)

H0 / t = 4.06

H0 / t = 5.03

H0 / t = 5.33

DETAIL OF MENISCUS CONFIGURATION AS THICKNESS FALLS

AS THE GAP-TO-THICKNESS RISES,

THE MENISCUS BECOMES MORE CURVED

AT THE TURNING POINT (H0 / t = 5.33), THE ANGLE BETWEEN

THE DIE AND THE FREE SURFACE IS ALMOST ZERO

BEAD BREAKS INTO RIVULETS

Page 42: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

0.001

0.01

0.1

1

10

0 10 20 30 40 50

Viscocapillary Model

Navier-Stokes

Cap

illa

ry N

um

ber

,

V /

Gap / Film Thickness

P = 0 NO INERTIAL EFFECTS

0.01

0.1

1

0 5 10 15 20

Viscocapillary Model

P = 0

P = 381

P = 762

P = 952.5

Cap

illa

ry N

um

ber

,

V /

Gap / Film Thickness

EFFECT OF INERTIA

Page 43: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

0.45

0.5

0.55

0.6

0.65

0.7

0 0.02 0.04 0.06 0.08 0.1 0.12

Posi

tion

alo

ng t

he

web

, X

(m

m)

Position across the bead, Y (mm)

Ca = 0.12

Ca = 0.31

Ca = 0.73

Ca = 1.00

DETAIL OF MENISCUS CONFIGURATION AS COATING SPEED RISES

Page 44: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

0.01

0.1

1

10

0 5 10 15 20

Viscocapillary Model

= 13 cP

= 17 cP

= 75 cP

= 22 cP

Ca

pil

lary

Nu

mb

er,

V /

Gap / Film Thickness

Extended Coating Window

Coating window presented

in the literature

Condition used to coat at:

= 22 cP, t = 0.5 mils, V = 230 ft/min

0.01

0.1

1

0 5 10 15 20

Viscocapillary Model

P = 0

P = 381

P = 762

P = 952.5

Ca

pilla

ry N

um

ber

,

V /

Gap / Film Thickness

EXPERIMENTS

MODEL

COATING WINDOW OF THE PROCESS IS LARGER THAN THE ONE

REPORTED PREVIOUSLY IN THE LITERATURE

CAN COAT THINNER BY GOING FASTER !

INERTIA CAN BE USED TO COUNTERACT

THE RECEDING ACTION OF THE

DOWNSTREAM MENISCUS AND

DELAY THE ONSET OF THE LOW FLOW LIMIT

(Carvalho and Keshghi, 2000)

Page 45: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Current Coating Fundamentals Challenges

Minimization of film thickness variation

for more uniform films;

Better understanding of coating of particulate suspensions

for more complex film structures;

Better understanding of multilayer coating process

for more complex film structures;

Discrete and patch coating;

Examples of recent advances and

how they can help the coating industry...

Page 46: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Current Coating Fundamentals Challenges

Minimization of film thickness variation

for more uniform films;

Better understanding of coating of particulate suspensions

for more complex film structures;

Better understanding of multilayer coating process

for more complex film structures;

Discrete and patch coating;

Examples of recent advances and

how they can help the coating industry...

Page 47: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Production lines are subjected to perturbations (even if very small…)

Coating thickness oscillation Gap oscillation

)()( 0 tHHtH m sin )()( 0 thhth msin

Romero e Carvalho (CES, 2008), Perez e Carvalho (JEM, 2011)

Roll radius is not constant, Mechanical vibrations, …

Goal Optimize slot coating process to minimize film thickness variation

due to ongoing disturbances of process conditions;

Transient Response of Coating Flow

Page 48: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Solution Method

Finite Element Method

Implicit time integration –

Newton’s method

Page 49: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Transient Response Hzf 1

Hzf 50

H(t) h(t)

Page 50: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Amplification factor is a function of

frequency of the imposed disturbance

process conditions

geometry of die lip

Effect of Coating Gap Effect of Vacuum pressure

Page 51: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Amplification factor at a given frequency can be mapped as

a function of process conditions.

Gap / Thickness

Dim

ensio

nle

ss V

acuum

Pre

ssure

0,7

0,6

0,5

0,5

0,4

0,4

0,3 0,3

0,20,2

4,03,53,02,52,01,5

40

35

30

25

20

15

10

Amplitude of film thickness oscillation may be reduced by a factor of 5

just by adjusting process conditions.

Hzf 3

Page 52: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Contour plot of amplification factor as a function of gap and vacuum pressure

Hzf 3

Solution has been implemented in a production line at Fuji Film, Japan.

Boundary Constraint Optimization algorithm.

)()()()(2

1)( 00000 xfxxbxxHxxxxq TT

)( 0

2 xfH )( 0xfb

Page 53: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Amplification factor map is a strong function of die lip geometry.

Gap / Thickness

Dim

ensio

nle

ss V

acuum

Pre

ssure

0,7

0,6

0,5

0,5

0,4

0,4

0,3 0,3

0,20,2

4,03,53,02,52,01,5

40

35

30

25

20

15

10

Gap / Thickness

Dim

ensio

nle

ss V

acuum

Pre

ssure

0,7

0,6

0,5

0,4

0,3

0,2

0,1 0,1

4,03,53,02,52,01,5

40

35

30

25

20

15

10

Die lip geometry may also be optimized to

reduce film thickness oscillation.

Page 54: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

In many applications, coating liquid is a particle suspension. Common approach is to study the flow as Newtonian or non-Newtonian with the liquid viscosity evaluated based on the avarage particle concentration. Experimental evidences show that suspensions of particles assume very non-uniform concentration distributions in nonhomogeneous shear flow. Local variation of viscosity and surface tension may change the flow pattern and consequently the process limits.

Final particle distribution on the coated film may not be uniform and have a strong effect on the drying process and product performance.

Particle suspension Coating process Coated film

?

Slot Coating of Particle Suspensions

Page 55: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

MATHEMATICAL MODEL OF COATING FLOW

Momentum conservation

Mass conservation

Particle Transport

0+)(+-- T

cp vvIvv

0= v

0 Nv c

0

0

Nn

nTn

vn

sss cc BCs along interface

)( sc

as first approximation

Page 56: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Particle Transport / Bulk

0 Nv c

Total flux of particles due to different migration mechanisms

Assume neutrally bouyant spherical, rigid particles; Neglect Brownian diffusion – particle size > 0.5 m; Diffuse flux model for particle migration proposed by Phillips et al (PF, 1992); Particle migration by two mechanisms:

1. Spatially varying particle-particle interaction frequency

2. Spatially varying liquid viscosity

NNN c

ccakcc 2N

cdc

dack

ack

22

22 N

Page 57: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Viscosity Model

1.82

1S m

c c

Empirical viscosity model for concentrated suspension developed by Krieger:

- suspension viscosity.

- continuous phase viscosity.

- volume fraction of particles.

- maximum packing fraction of particles. m

c

cs

cP60)(4.0

68.0cP;12

00

cc

cms

In this work:

Page 58: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

SOLUTION METHOD

Unknown physical domain is mapped to a fixed reference domain; Mapping is described by a set of differential diffusion equations:

The set of PDE is solved by Galerkin´s / Finite Element Method; Need to modify system in order to compute derivative of shear rate (second derivative of velocity field) Deformation rate tensor is treated as an independent field that is also expanded in terms of finite element basis functions: I

I

vvG

)(tr

Page 59: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

RESULTS

Inlet condition: uniform concentration profile: Feed Slot: Particles migrate towards the middle of the feed slot (zero shear rate)

4.0)( 0 cc x

Low particle concentration at the walls; Flow is lubricated; Possible particle agglomeration.

Upstream gap: Particles migrate towards zero shear rate layer.

Lower particle concentration at die lip; Flow is lubricated; Upstream meniscus position is shifted; Effect on low vacuum limit.

8.1;2.1;cP12;100;dyn/cm60;m/s1.0 kkmHV cs

Page 60: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Film thickness (flow rate) has a strong effect on deformation rate distribution under the die lip; Consequently, it has a strong effect on the particle concentration in the coating bead and final coated layer;

Couette Poiseuille

+ =

Couette Poiseuille

+ =

Couette Poiseuille

+ = TH

INN

ER

CO

AT

ING

TH

ICK

NE

SS

3

0Ht

3

0Ht

2

0Ht

Almost rectilinear flow Couette (drag) + Poiseuille (pressure gradient)

const

0

0

Page 61: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

250 0H

mt Film thickness equal to half of the gap

0.35

0.36

0.37

0.38

0.39

0.4

0.41

0.42

0.43

0 0.01 0.02 0.03 0.04 0.05

Co

nce

ntr

atio

n

y

Flux related to shear rate gradient is zero. Weak particle migration after feed slot. High particle concentration at center of feed slot is convected to final coated layer.

Concentration field at coated layer

Region of high particle concentration in the middle of the coated layer. Possible effect on final structure and drying process.

Page 62: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

337 0H

mt Film thickness close to one-third of the gap

0.36

0.37

0.38

0.39

0.4

0.41

0.42

0.43

0 0.01 0.02 0.03 0.04

c

y

Strong flux towards the zero-shear rate layer attached to the die lip; High particle concentration attached to the die lip is convected to top of the coated film.

Concentration field at coated layer

Region of high particle concentration on the top of the coated layer. Possible effect on final structure and drying process.

Page 63: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

314 0H

mt Film thickness less than one-third of the gap

0.36

0.37

0.38

0.39

0.4

0.41

0.42

0.43

-0.001 0.004 0.009 0.014

c

y

Recirculation under the the die lip; High concentration inside the recirculation (near close packing) – particle agglomeration?; High concentration gradient in the free surface – Strong Marangoni effect ?

Region of high particle concentration on the top of the coated layer.

Page 64: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Final Remarks

Slot coating fundamentals is well understood for two-dimensional, steady-state operation – coating window studies;

Fundamental understanding pays off

objectives need to be well defined for industrial use Coating research is addressing current and more complex issues faced by the coating industry;

Page 65: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot
Page 66: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Thank you!

You are welcome to visit PUC and Rio de Janeiro

Page 67: Fundamentals of Slot Coating Process - AIMCAL · Fundamentals of Slot Coating Process Prof. Marcio Carvalho ... Prediction of failure mechanisms and coating window Roll coating Slot

Sponsored by: The International Society of

Coating Science and Technology (www.iscst.org)

In Cooperation with: The European Coating

Symposium and The Japan Coating Symposium

Highlights

Interaction across industrial

sectors and between

academia and industry

Special sessions focused

on energy

Vendor Exhibit

Welcome Reception

Networking Sessions

Short Course.

Extended Abstract book

The ISCST Symposium provides a forum for researchers with both academic and industrial

perspectives on coating science and technology to discuss the latest research on the deposition

and solidification of thin liquid films. The Symposium features contributions on both fundamental

and applied research by many of the experts in the field from Europe, Asia, and the Americas.

The Symposium format is designed to provide opportunities for networking and for the exchange

of information between scientists and engineers who are working on coating process and

materials development and manufacturing.

Symposium Chair: Prof. Marcio Carvalho, PUC-Rio, [email protected]

Symposium Co-Chair: Dr. Brent Bell, W.L. Gore & Associates Inc., [email protected]

ISCST President: Prof. Andrew Hrymak, The U. of Western Ontario, [email protected]

Symposium Facilitator: Ms. Ashley Wood, AIMCAL, [email protected]

www.iscstsymposium.org