• Korean Chemical Engineering Research
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• v.49 no.3
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• pp.314-319
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• 2011

In this study, the flow behavior of Newtonian and non-Newtonian coating liquids inside slot die has been scrutinized for the purpose of optimal internal die design in slot coating system from three-dimensional computations by CFD Fluent solver. A hybrid slot die could be optimally designed by changing the chamber or manifold structure to guarantee the uniform velocity distribution of coating liquids at die exit. Especially, for the non-Newtonian coating liquids, the length of coat-hanger for the uniform coating has been properly chosen, according to the degree of their shearthinning properties.

• Journal of the Semiconductor & Display Technology
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• v.22 no.4
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• pp.119-123
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• 2023

This study is normal orientation technology of slit coating equipment to improve the quality of curved displays. Currently, the demand for curved displays is increasing significantly due to advantages such as screen immersion or design in various industries. Accordingly, changes in the display coating process are essential. In the curved display coating process, unlike the existing flat coating process, the nozzle must be rotated along the curvature of the curved surface to spray the coating solution. The coating solution must be applied while maintaining a uniform thickness. If the thickness of the coating liquid applied to the target surface is non-uniform, the quality of the product may be degraded such as image quality deterioration and light spreading. This paper presents technology and experimental results for keeping the nozzle of slit coating equipment perpendicular to the curved surface and is expected to contribute to the quality improvement of curved displays.

• Polymer(Korea)
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• v.38 no.5
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• pp.640-644
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• 2014

As a process of plat panel display production, slot coating is widely used for the coating of photoresist on a wide glass substrate. A uniform coating thickness is important, and the coating uniformity is divided into nozzle and machine directions. The machine and nozzle directions coating uniformities are influenced by the operation condition of coater and flow uniformity inside the die, respectively. Non-uniform coating during steady coating process occurs according to those factors, however, non-uniform coating along the machine and nozzle directions has been observed at the beginning of coating by unsteady flow. In this study, steady and unsteady state flow simulations have been performed and compared with experiment to examine the causes of non-uniform coating. Computational results exhibited that it took a time to get a uniform pressure distribution at whole inside the die, and during this period of time edge regions showed lower exit velocity compared with center region. Subsequently edge regions had thinner coated layers than center region. However edge regions showed higher exit velocity than center region after steady state, and this made edge regions had thicker coated layer than center region.

• Proceedings of the Korean Society of Rheology Conference
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• 2006.06a
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• pp.81-84
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• 2006

Slot coating process, in continuous and patch modes, has been applied for the many precise coating products, e.g., flat panel displays and second batteries. However, manufacturing uniform coating products is not a trivial task at high-speed operations because various flow instabilities or defects such as leaking, bubbles, ribbing, and rivulets are frequently observed in this process. It is no wonder, therefore, that many efforts to understand the various aspects of dynamics and coating windows of this process have been made both in academia and industry. In this study, as the first topic, flow dynamics within the coating bead in slot coating process has been investigated using the one-dimensional viscocapillary model by lubrication approximation and two-dimensional model by Flow-3D software. Especially, operability windows in both 1D and 2D cases with various slot die lip designs have been successfully portrayed. Also, effects of process conditions like viscosity and coating gap size on slot coating window have been analyzed. Also, some experiments to find minimum coating thickness and coating windows have been conducted using slot die coater implemented with flow visualization device, corroborating the numerical results. As the second topic, flow dynamics of both Newtonian and Non-Newtonian fluids in patch or pattern slot coating process, which is employed in manufacturing IT products such as secondary batteries, has been investigated for the purpose of optimal process designs. As a matter of fact, the flow control in this system is more difficult than in continuous case because od its transient or time-dependent nature. The internal die and die lip designs for patterned uniform coating products have been obtained by controlling flow behaviors of coating liquids issuing from slot. Numerical simulations have been performed using Fluent and Flow-3D packages. Flow behavior and pressure distribution inside the slot die has been compared with various die internal shapes and geometries. In the coating bead region, efforts to reduce irregular coating defects in head and tail parts of one patterned coating unit have been tried by changing die lip shapes. It has been concluded that optimal die internal design gas been developed, guaranteeing uniform velocity distribution of both Newtonian and shear thinning fluids at the die exit. And also optimal die lip design has been established, providing the longer uniform coating layer thickness within one coating unit.

• Journal of the Korean Society for Precision Engineering
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• v.30 no.3
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• pp.317-323
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• 2013

In-mold coating is a reactive fluid designed to improve the surface quality of injection molded thermoplastic substrate in functional and cosmetic properties. In this study, a mixing head for in-mold coating was designed, and mixing characteristics of two-component polyurethane flowing through runner were investigated based on flow simulations. In order to achieve uniform mixing of two components injected through straight mixing head, an impingement aftermixer was used in runner design. Semi-circular cross-section was better than circular one for runners for uniform mixing. With increasing runner length and flow rate, mixing became more uniform. In addition, the degree of mixing was more improved with decreasing viscosity of isocyanate.

• Tribology and Lubricants
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• v.24 no.2
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• pp.96-103
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• 2008

PTFE is generally utilized as the form of composites with adding various fillers. The purpose of this paper lies on clarifying the friction and wear properties of the PTFE coating layer on steel. Especially, the effects of PTFE powder size for coating and surface roughness of the counter material on the properties are investigated. Sliding friction and wear tests are conducted at several sliding speeds by employing two types of PTFE coating layer using different powder sizes. One type of coating layer is composed of uniform fine powder, whereas the other type is made up of mixture powder of different sizes. As results, it is found that PTFE coating layer are effective to improve the wear resistance and to reduce the friction coefficient. It is clear that PTFE coating layers are abrasively removed by asperities of the counter material during sliding contact. However, PTFE coating layer with uniform fine powder shows somewhat better wear resistance than that with mixture powder of different sizes in low sliding speed region. It can be seen that the wear of the coating layer are drastically reduced because wear fragment from counter material are transferred to the coating layer. On the other hand, friction coefficient is shown not to be directly related with PTFE powder size in coating layer.

• Journal of Powder Materials
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• v.24 no.1
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• pp.46-52
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• 2017

Fecralloy coating layer with large surface area is suitable for use as a filter media for efficient removal of hot gaseous pollutants exhausted from combustion processes. For uniform preparation of a Fecralloy coating layer with large surface area and strong adhesion to substrate, electrospray coating and thermal treatment processes are experimentally optimized in this study. A nano-colloidal solution with 0.05 wt% Fecralloy nanoparticles is successfully prepared. Optimized electrospraying conditions are experimentally discovered to prepare a uniform coating layer of Fecralloy nano-colloidal solution on a substrate. Drying the electrospray coated Fecralloy nano-colloidal solution layer at $120^{\circ}C$ and subsequent heating at $600^{\circ}C$ are the best post-treatment for enhancing the adhesion force and surface roughness of the Fecralloy coating layer on a substrate. An electrospray coating system, consisting of several multi-groove nozzles, is also experimentally confirmed as a reasonable device for uniform coating of Fecralloy nano-colloid on a large area substrate.

• Korean Journal of Materials Research
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• v.17 no.2
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• pp.86-90
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• 2007

The organic-capped Ba-Ti-O nanolayers were coated uniformly on spherical Ni particles for multilayer ceramic capacitor (MLCC) applications via the formation of Ti-hydroxide nano-coating layers and their subsequent reaction with Ba-stearate at $180^{\circ}C$. The capping of organic shell on oxide coating layer changed the hydrophilic surface structure into hydrophobic one, which significantly improved the dispersion behavior in hydrophobic solvents such as terpineol and butanol. In addition, the uniform coating of Ba-Ti-O layer was advantageous to prevent Ni oxidation. This method provides a useful chemical route to fabricate organic-soluble Ba-Ti-O coated Ni particles for a highly integrated passive component.

• Journal of the Korean Ceramic Society
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• v.36 no.5
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• pp.513-520
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• 1999

Alumina-coated SiC whiskers wee prepared by the calcination (1150$^{\circ}C$, 1h, Ar) of the alumina hydrate layer which was precipitated homogeneously on whisker surface from a solution of Al2(SO4)3 and urea as a precipitant. In addition carbon coated SiC whiskers were prepared by the pyrolysis (1000$^{\circ}C$, 4h Ar) of phenolic resin coated whisker. The effects of coating conditions on the thickness and morphology of the coated layers were examined by SEM and TEM. It was found that Al2O3-coating layers become thinner and more uniform with decreasing the Al2(SO4)3 concentration. Thin (0.075-0.1$\mu\textrm{m}$) and uniformly alumina-coating layers were obtained at the Al2(SO4)3 concentration 0.010mol/l. On the other han carbon-coating layers were uniform but very thin (5-16 nm) in thickness. For thicker carbon-coating layers ethanol as a disperse medium was found to be more efficient compared tousing acetone.

• Journal of the Korean Society for Precision Engineering
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• v.32 no.10
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• pp.897-902
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• 2015

This study reports on a uniform resin coating method by using a doctor blade type dispenser. For high productivity, continuous imprint-lithography has been studied, and developed fabrication systems are used in several applications such as anti-reflection films, dry adhesives, and water collecting surfaces. In the continuous fabrication field, researchers have typically focused on patterning and demolding procedures. During the roll-to-roll fabrication process, however, the uniform resin coating process is also important in order to obtain a high quality product, which can be evaluated by uniform thickness, precise geometric expressions, and a thin residual layer. To achieve these, a doctor blade type dispenser was designed and fabricated. As a result, thickness of coated resin was well controlled by modulating the flow rate of the resin and blading gap. In addition, a very thin layer coating process (${\sim}10{\mu}m$) was achieved by softly contacting the blade on the substrate.