Skip to main content
SpringerLink
Log in

Computational fluid dynamics model for thickness and uniformity prediction of coating layer in slot-die process

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

A three-dimensional computational fluid dynamics model to analyze the dynamics of ink at the outlet of a slot-die coater and wet coated layer thickness is presented in this paper. This model can be used to estimate the thickness deviation of the coated layer in the transverse direction, which cannot be obtained by using the conventional two-dimensional model. The internal geometry of the slot-die coater was statistically optimized by using the Box–Behnken design of experiment. Experimental results show that the thickness deviation is improved by 71% in the slot-die coater having an optimal internal geometry and inlet flow rate. The developed model is expected to be useful in obtaining the desired coating conditions and geometry of the slot-die coater without costly and time-consuming experiments.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8

Similar content being viewed by others

References

  1. Keränen K, Korhonen P, Rekilä J, Tapaninen O, Happonen T, Makkonen P, Rönkä K (2015) Roll-to-roll printed and assembled large area LED lighting element. Int J Adv Manuf Technol 81:529–536. https://doi.org/10.1007/s00170-015-7244-6

    Article  Google Scholar 

  2. Lee J, Kim S, Lee C (2019) Effect of radial stress on the adhesive force of a wound roll in industrial roll-to-roll manufacturing system. Int J Precis Eng Manuf 19(3):411–415. https://doi.org/10.1007/s12541-018-0049-4

    Article  Google Scholar 

  3. Park J, Lee J, Park S, Shin K-H, Lee D (2016) Development of hybrid process for double-side flexible printed circuit boards using roll-to-roll gravure printing, via-hole printing, and electroless plating. Int J Adv Manuf Technol 82:9–12. https://doi.org/10.1007/s00170-015-7507-2

    Article  Google Scholar 

  4. Lee C (2018) Stresses and defects in roll products: a review of stress models and control techniques. Int J Precis Eng Manuf 19(5):781–789. https://doi.org/10.1007/s12541-018-0094-z

    Article  Google Scholar 

  5. Lee J, Kim S, Lee C (2019) Surface drying for brittle material coating without crack defects in large-area roll-to-roll coating system. Int J Precis Eng Manuf Green Tech:1–8. https://doi.org/10.1007/s40684-019-00104-6

    Article  Google Scholar 

  6. Park J, Kim S, Lee C (2018) An analysis of pinned edge layer of slot-die coated film in roll-to-roll green manufacturing system. Int J Precis Eng Manuf Green Tech 5(2):247–254. https://doi.org/10.1007/s40684-018-0025-6

    Article  Google Scholar 

  7. Romero O, Suszynski W, Scriven L, Carvalho M (2004) Low-flow limit in slot coating of dilute solutions of high molecular weight polymer. J Non-Newtonian Fluid Mech 118(2):137–156. https://doi.org/10.1016/j.jnnfm.2004.03.004

    Article  Google Scholar 

  8. Lee J, Nam J (2016) A simple model for viscoplastic thin film formation for coating flows. J Non-Newtonian Fluid Mech 229:16–26. https://doi.org/10.1016/j.jnnfm.2015.12.012

    Article  MathSciNet  Google Scholar 

  9. Romero O, Scriven L, Carvalho M (2006) Slot-coating of mildly viscoelastic liquids. J Non-Newtonian Fluid Mech 138(2):63–75. https://doi.org/10.1016/j.jnnfm.2005.11.010

    Article  MATH  Google Scholar 

  10. Chang Y-R, Chang H-M, Lin C-F, Liu T-J, Wu P-Y (2006) Three minimum wet thickness regions of slot die coating. J Colloid Interface Sci 308(1):220–230. https://doi.org/10.1016/j.jcis.2006.11.054

    Article  Google Scholar 

  11. Sharma AK, Tiwari AK, Dixit AR (2018) Prediction of temperature distribution over cutting tool with alumina-MWCNT hybrid nanofluid using computational fluid dynamics (CFD) analysis. Int J Adv Manuf Technol 97:427–439. https://doi.org/10.1007/s00170-018-1946-5

    Article  Google Scholar 

  12. Park J, Shin K, Lee C (2015) Improvement of cross-machine directional thickness deviation for uniform pressure-sensitive adhesive layer in roll-to-roll slot-die coating process. Int J Precis Eng Manuf 16(5):937–943. https://doi.org/10.1007/s12541-015-0122-1

    Article  Google Scholar 

  13. Park J, Shin K, Lee C (2016) Optimized design for anti-reflection coating process in roll-to-roll slot-die coating system. Robot Comput Integr Manuf 30(10):432–441. https://doi.org/10.1016/j.rcim.2014.02.001

    Article  Google Scholar 

  14. Hecht DS, Hu L, Irvin G (2011) Emerging transparent electrodes based on thin films of carbon nanotubes, graphene, and metallic nanostructures. Adv Mater 23(13):1482–1513. https://doi.org/10.1002/adma.201003188

    Article  Google Scholar 

  15. Shin K, Park J, Lee C (2016) A 250-mm-width, flexible, and continuous roll-to-roll slot-die coated carbon nanotube/silver nanowire film fabrication and a study on the effect of anti-reflective overcoat. Thin Solid Films 598:95–102. https://doi.org/10.1016/j.tsf.2015.12.004

    Article  Google Scholar 

  16. Kim S, Kim SY, Chung MH, Kim J, Kim JH (2015) A one-step roll-to-roll process of stable AgNW/PEDOT: PSS solution using imidazole as a mild base for highly conductive and transparent films: optimizations and mechanisms. J Mater Chem C 3(22):5859–5868. https://doi.org/10.1039/C5TC00801H

    Article  Google Scholar 

  17. Krebs FC, Fyenbo J, Jørgensen M (2010) Product integration of compact roll-to-roll processed polymer solar cell modules: method and manufacture using flexographic printing, slot-die coating and rotary screen printing. J Mater Chem 20(41):8994–9001 5868. https://doi.org/10.1039/C0JM01178A

    Article  Google Scholar 

  18. Schmidt TM, Larsen-Olsen TT, Carlé JE, Angmo D, Krebs FC (2015) Upscaling of perovskite solar cells: fully ambient roll processing of flexible perovskite solar cells with printed back electrodes. Adv Energy Mater 5(15): Paper No. 02164. https://doi.org/10.1002/aenm.201500569

    Article  Google Scholar 

  19. Lima FAS, Beliatis MJ, Roth B, Andersen TR, Bortoti A, Reyna Y, Castro E, Vasconcelos IF, Gevorgyan SA, Krebs FC, Lira-Cantu M (2016) Flexible ITO-free organic solar cells applying aqueous solution-processed V2O5 hole transport layer: an outdoor stability study. APL Mater 4(2): Paper No. 1500569. https://doi.org/10.1063/1.4942638

    Article  Google Scholar 

  20. Helgesen M, Carle JE, Krebs FC (2013) Slot-die coating of a high performance copolymer in a readily scalable roll process for polymer solar cells. Adv Energy Mater 3(12):1664–1669. https://doi.org/10.1002/aenm.201300324

    Article  Google Scholar 

  21. Sandström A, Dam HF, Krebs FC, Edman L (2012) Ambient fabrication of flexible and large-area organic light-emitting devices using slot-die coating. Nat Commun 3(1002). https://doi.org/10.1038/ncomms2002

  22. Lee J, Kim S, Lee C (2019) Large area electrolyte coating through surface and interface engineering in roll-to-roll slot-die coating process. J Ind Eng Chem 76(25):443–449. https://doi.org/10.1016/j.jiec.2019.04.011

    Article  Google Scholar 

  23. Lee J, Park J, Jeong H, Shin K, Lee D (2016) Optimization of printing conditions for microscale multiline printing in continuous roll-to-roll gravure printing. J Ind Eng Chem 42(10):131–141. https://doi.org/10.1016/j.jiec.2016.07.031

    Article  Google Scholar 

  24. Lee C, Kang H, Kim C, Shin K (2010) A novel method to guarantee the specified thickness and surface roughness of the roll-to-roll printed patterns using the tension of a moving substrate. J Microelectromech 19(5):1243–1253. https://doi.org/10.1109/JMEMS.2010.2067194

    Article  Google Scholar 

Download references

Funding

This work was supported by the Energy Efficiency & Resources of the Korea Institute of Energy Technology Evaluation and Planning (KETEP) grant funded by the Korea Government Ministry of Knowledge Economy (No.20173010032140)

Author information

Authors and Affiliations

  1. Department of Mechanical Design and Production Engineering, Konkuk University, 120, Neungdong-ro, Gwangjin-gu, Seoul, 05029, South Korea

    Seongyong Kim & Jongsu Lee

  2. Department of Mechanical Engineering, Konkuk University, 120, Neungdong-ro, Gwangjin-gu, Seoul, 05029, South Korea

    Changwoo Lee

Authors
  1. Seongyong Kim
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jongsu Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Changwoo Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Changwoo Lee.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Kim, S., Lee, J. & Lee, C. Computational fluid dynamics model for thickness and uniformity prediction of coating layer in slot-die process. Int J Adv Manuf Technol 104, 2991–2997 (2019). https://doi.org/10.1007/s00170-019-04093-3

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-019-04093-3

Keywords

Search

Navigation