Intermittent coating

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  • BACKGROUND Surface energy modica=on

    Pump Control Valve control (=ming) Physical movement (=ming)

    Physical Posi=on Liquid (vapor) adsorp=on

    Distance Roughness Concentra=on


    Con=nuous Discrete Panel

    Process limita=ons Head Tail Line speed Start/stop phenomenon


    US 4,938,994 Edward Choinski (1990)

    Flow control Mechanical movement


    US 5,360,629 Thomas Milbourn and Jerry Barth (1994)

    Con=nuous web 3-way valve

    Time limita=on Mul=ple sta=ons


    US 5,824,156 Watanabe et al (1998)

    Con=nuous web Internal shut-o bar

  • SPECIFICATIONS Coat width = 340 mm Coat length = 680 mm Intermibent coa=ng capability required up to 10 mpm (30

    mpm in further study) with maximum 3 mm tail allowed Crossweb varia=on tolerance based o weight (5 +/-0.15

    mg/cm2). Required coa=ng speed: at least 10 mpm for a slurry with

    loading of 6 mg/cm2 and 50 solid % Coa=ng edge quality to match crossweb coa=ng varia=on

    capability Tension control improvement to match downweb coa=ng

    varia=on capability based o weight (5 +/-0.15 mg/cm2)

  • SPECIFICATIONS Head & Tail development

    Crossweb caliper control Velocity gradient Pressure gradient Volumetric ow

    Edge eects Surface tension Film stretching Die swell

    Patch control Computer control and programming (die posi=oner, valve and

    web control) Electrical response (valve and physical movement)


    Anode Water-based (shear thinning) Copper substrate

    Cathode NMP-based (shear thinning) Aluminum substrate


    Slot die setup Oset = 0 Lip face (upstream and downstream) = 762 micron (0.030 inch)

    Shim thickness = 500 micron (20 mil) Coa=ng gap = 25 micron (1 mil) Coa=ng width = 340 mm (13.38 inch)


    Simula=on feedback Pressure Velocity Volumetric ow Mass ow

    Tension and compression Flow stability Stagna=on zones Die swell

  • RESULTS Line speed increase

    Parallellism worsens Reac=on =me

    Pressure increase Fluid velocity increase Measure and balance around valve

    Edge eects Stresses (surface tension, lm stretching or die swell) Draw ra=o (substrate speed/uid speed) Slot die design and simula=on

    Air Excessive uid ow

  • CONCLUSION 10 mpm acceptable applica=on speed Best setup (reduced head/tail, reduced edge bead and

    improved parallel edge) Flow control Mechanical movement

    FUTURE Increased line speed (30 mpm +) Alterna=ve technologies Mul=ple sta=ons Surface modica=on eect Vacuum eect