Chapter 8: Applications and Industries

Core Applications

Slot die coating excels in:

• Lithium-Ion Batteries: Electrode and separator layers for efficiency; uniform thickness improves charge distribution.

• Renewable Energy: Photovoltaics and fuel cells for thin films; multi-layers enhance efficiency.

• Pharmaceuticals: Transdermal patches and diagnostic strips; precise dosing via controlled viscosity.

• Electronics: Flexible displays and PCBs; defect-free for conductivity.

• Packaging: Adhesives, barriers, and decorative coatings; high speeds for throughput.

Other industries: Automotive (e.g., anti-corrosion), aerospace (lightweight composites), textiles (functional finishes), medical devices (biocompatible layers).

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Benefits in Practice

Reduces waste by 30%, scales easily, supports high throughput. For example, in batteries, optimizing particle size in slurries ensures even distribution.

• Lithium-Ion Batteries: Slot die coating is used for electrode and separator layers, enabling precise material deposition in high-volume production.

  • Ensures uniform thickness of active materials, improving battery efficiency and energy density by up to 20%.

  • Reduces material waste through pre-metered application, lowering costs in large-scale manufacturing.

  • Enhances safety by achieving consistent separator insulation, minimizing risks like short circuits.

• Renewable Energy: Applied in thin-film photovoltaics and fuel cells for catalyst and layer coatings.

  • Provides uniform thin films that boost light absorption and conversion efficiency in solar cells.

  • Supports multi-layer deposition for complex structures, optimizing chemical reactions in fuel cells.

  • Enables scalable R2R processing, reducing production time and promoting sustainable energy solutions.

• Pharmaceuticals: Utilized for transdermal patches, diagnostic strips, and medical device coatings.

  • Delivers precise drug dosages in patches, ensuring consistent release rates for better therapeutic outcomes.

  • Achieves uniform reagent layers on strips, improving accuracy in diagnostic tests like glucose monitoring.

  • Minimizes contamination in cleanroom environments, complying with strict regulatory standards.

• Electronics: Employed in flexible displays, printed circuit boards (PCBs), and touch screens.

  • Creates defect-free conductive layers for OLED screens, enhancing display quality and flexibility.

  • Applies even solder masks or inks on PCBs, improving electrical performance and reliability.

  • Supports high-speed coating for mass production, reducing defects in consumer electronics.

• Packaging: Used for adhesive, barrier, laminate, and decorative coatings in food, beverage, and consumer goods.

  • Provides multilayer barriers against moisture, oxygen, and grease, extending shelf life and enabling eco-friendly materials.

  • Enhances visual appeal with gloss, matte, or holographic finishes, improving product marketability.

  • Reduces waste in high-throughput lines, supporting sustainable packaging initiatives.

• Automotive and Aerospace: Applied in anti-corrosion coatings, lightweight composites, and functional surfaces.

  • Improves durability with uniform protective layers, extending vehicle lifespan and reducing maintenance.

  • Enables precise application on complex substrates, enhancing aerodynamics and fuel efficiency in aerospace parts.

• Textiles and Medical Devices: Used for functional finishes like water-repellent coatings and biocompatible layers.

  • Adds value to fabrics with even treatments, improving comfort and performance in apparel.

  • Ensures sterility and adhesion in devices like stents, enhancing biocompatibility and patient safety.

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As per ARC resources, R2R applications drive innovation in sustainable manufacturing.