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Avoiding surface instability and slurry jamming in simultaneous multilayer coating of structured particulate films

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Abstract

Simultaneous multilayer coating techniques are widely known, but their industrial application remains limited to narrow market sectors. One barrier to adoption may be the mismatch between industries that are familiar with such processes but have no need, and industries that have need but are not familiar. Moreover, there are application-specific technical challenges to developing multilayer-coating processes. In this article, we describe our resolution of two specific issues in simultaneous multilayer coating of all-aqueous highly loaded slurries for new and emerging energy applications. The first issue is particle jamming (associated with shear-thickening) of the highly loaded slurries in the die internals, which we alleviated by adding small amounts of viscosity modifiers without reducing the solid loading. The second issue is a Marangoni-driven surface instability that resembles top layer de-wetting, which we solved by carefully selecting surfactants to tune the dynamic surface tensions of each slurry. Both issues were resolved early in a step-wise development, saving significant development cost which in our case was driven by expensive materials.

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Acknowledgments

This work is partially supported by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) under the Advanced Manufacturing Office, Advanced Manufacturing Projects for Emerging Research Exploration Award No. DE-EE0008323. We would like to acknowledge Dr. Peter M. Schweizer (Schweizer Coating Consulting GmbH) for valuable consultations on the theory and practice of multilayer slot and slide coating.

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Authors and Affiliations

  1. Saint-Gobain Research North America, Northborough, MA, USA

    J. Alex Lee, Aaron Kessman, David Shackleford, Martin Z. Bazant, Brian Barry, Courtland Chapman & Jeff Peet

  2. Department of Chemical Engineering, MIT, Cambridge, MA, USA

    Martin Z. Bazant

  3. Department of Mathematics, MIT, Cambridge, MA, USA

    Martin Z. Bazant

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  1. J. Alex Lee
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  2. Aaron Kessman
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  3. David Shackleford
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  4. Martin Z. Bazant
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  5. Brian Barry
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  6. Courtland Chapman
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  7. Jeff Peet
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Correspondence to J. Alex Lee.

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Lee, J.A., Kessman, A., Shackleford, D. et al. Avoiding surface instability and slurry jamming in simultaneous multilayer coating of structured particulate films. J Coat Technol Res 19, 131–142 (2022). https://doi.org/10.1007/s11998-021-00542-5

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  • DOI: https://doi.org/10.1007/s11998-021-00542-5

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