Bubble Defect Generation Mechanism in Slot Die Coating of High-Viscosity Fluids.

Slot die coating is a widely used technique for the production of high accuracy films. One of the main challenges in slot die coating processes is determining the optimal range of operating parameters to prevent defects, such as bubbles, in high-viscosity films. In this study, both simulation and experimental methods were used to investigate the changes in the upstream meniscus under various coating parameters. Two types of air entrainment processes were considered, dominated by fluid inertia and viscous force. The formation of anticlockwise and clockwise vortex flows near the bottom of the upstream meniscus was found to alter the apparent dynamic contact angle of the upstream meniscus, leading to fluctuations in the apparent dynamic contact angle within a range of 70°-75° to 135°-140°. These fluctuations eventually resulted in air entrainment. This research is important for improving the quality and efficiency of slot die coating processes.

Effects of bubbles on particle dynamic behavior and concentration distribution in High-viscosity liquid under negative pressure.

The vacuum method is a widely adopted technique for eliminating bubbles from polymers containing particles. To investigate the influence of bubbles on the behavior of particles and the concentration distribution in high-viscosity liquids under negative pressure, experimental and numerical methods have been employed. The experimental findings demonstrated a positive correlation between the diameter and rising velocity of bubbles and the negative pressure. As the negative pressure increased from - 10 kPa to - 50 kPa, the position of the region where the particles were concentrated in the vertical direction was elevated. Furthermore, when the negative pressure exceeded - 50 kPa, the particle distribution became sparse and layered locally. The Lattice Boltzmann method (LBM) integrated with the discrete phase model (DPM) was utilized to investigate the phenomenon, and the outcomes revealed that rising bubbles have an inhibitory effect on particle sedimentation, and the extent of inhibition was determined by the negative pressure. In addition, vortexes generated by differences in the rising velocity between bubbles resulted in a particle distribution that was sparse and layered locally. This research provides a reference for achieving desired particle distributions using a vacuum defoaming approach and should be further studied to extend its applicability to suspensions containing particles with different viscosities.