Chapter 6: Setting Up Slot Dies in a Coating Line

Integration into Roll-to-Roll Systems

Slot dies integrate into coating lines via positioners for precise alignment, achieving repeatability within 2.54 microns. Mount in any orientation; use vacuum systems to stabilize substrates and prevent air entrapment, especially for low-viscosity fluids.

​

​

​

​

​

​

​

​

​

 

 

Ancillary equipment includes:

• Precision pumps for flow control, selected based on viscosity (detailed in Chapter 7).

• Heated lines for viscosity management, maintaining consistent temperature.

• Turning bars and edge guides for substrate handling, preventing wander.

​

Step-by-Step Setup

1. Align die with substrate path using offset features.

2. Connect fluid delivery and check for leaks; prime to remove air.

3. Calibrate gap using shims, considering particle size to avoid blockages.

4. Test at low speeds (e.g., 10 m/min), monitoring bead formation.

5. Scale up, adjusting for factors like solids % which affect pressure needs.

 

Safety: Ensure material compatibility to avoid reactions; maintain clean environments to minimize particle contamination.

​

​

​​

​

​

​

​

​

​

​

​

​

Proper setup reduces startup defects by ensuring uniform flow from the start.