Computational Fluid Dynamics for Slot Die Coating Analysis

Allyce Jackman, Flow Science, Inc.

Research into slot die coating processes has grown steadily as more industries adopt this technology for manufacturing battery electrodes, electronic displays, adhesives, and much more. This presentation will discuss how simulations using computational fluid dynamics (CFD) and the volume of fluid (VOF) method provide robust solutions for viscous surface tension-driven flows. I will demonstrate how CFD provides insights into coating window development, the reduction of defects such as air entrapment, ribbing, and edge defects, achieving process stability for higher throughput, and internal flow analysis for manifold design. In addition to analysis of processing parameters and die design, we will cover non-Newtonian and viscoelastic rheology, and the effect this has on flowability within the die as well as coating homogeneity. A case study provided by Roche Diagnostics on modeling slot die coating for electrochemical test trips, as well as examples done in collaboration with 3M on modeling internal slot die flow and edge guides will be included.