Precision Stripe Coating by Nonmeniscus
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1 Precision Stripe Coating by Nonmeniscus Guide Slot Die Naoki S. Rikita Technical Director R&D Marketing Division, MMC Ryotec 7F. KFC BLDG 1-6-1, YOKOAMI, SUMIDA-KU, TOKYO, JAPAN Phone: Fax: RDM
2 Contents Slot Die overview Stripe Coating Stripe Coating with Shim Stripe Coating with shim+meniscus guide Non Meniscus guide type Direct groove type Tungsten Carbide Comparison to Stainless steel Computer simulation and Fluid analysis Super polishing and high precision Conclusion 2
3 Slot Die Overview Body Tungsten Carbide lips Stainless steel lips Stainless steel body 3
4 What is Slot Die? Slot Die overview Functional coating apparatus used in roll to roll and batch coating applications Slot Die Cavity Backup roll Film Machine stage Substrate Roll process Single process R2R S2S 4
5 Stripe coating by Slot Die
6 Stripe coating by Slot Die OPV, OLED lighting Must be same width. Hot Spot Issue
7 Stripe Coating with shim Cavity Stripe shim
8 Stripe Coating with shim Meniscus
9 Stripe Coating with shim The quality of slits Substrate Coating Gap Sharp corner edge: If it is not sharp, leakage and diffusion happens. All slits must be same width. Precision cutting : Straightness, same dimension Cutting quality : smoothness, sharp edge
10 Stripe Coating with shim If the quality of slits are not good, the width of stripes are not in same. Problems Hot spot issue on OPV Cross talk issue Conduction (Short) issue Stripe Shim vibration vibration Another issue : Shim vibration
11 Stripe Coating with shim+meniscus guide Cavity Stripe shim Meniscus guide Anti shim vibration Meniscus guide Meniscus guide may prevent shim vibration.
12 Stripe Coating with shim+meniscus guide Meniscus guide
13 Stripe Coating with shim+meniscus guide 100um or less Meniscus Guide Stripe Shim vibration vibration Meniscus guide is not perfect to obtain high precision stripe coat.
14 Non Meniscus guide type Direct groove type Precision Stripe Coating by Non-meniscus Guide Slot Die
15 Precision Stripe Coating by Non-meniscus Guide Slot Die
16 Precision Stripe Coating by Non-meniscus Guide Slot Die
17 Tungsten Carbide. R:2-3μm (Stainless steel. R: 20μm) Shim. R:20μm vibration vibration
18 Precision Stripe Coating by Non-meniscus Guide Slot Die High precision polishing process Progressed 90 degree side wall Edge R : 2-3um 1um less Corner R : 200um 15um
19 Precision Stripe Coating by Non-meniscus Guide Slot Die CAE capability Fluid analysis
20 20 Tungsten Carbide
21 Why Tungsten Carbide? Tungsten Carbide Tungsten carbide is one of the metal which is the hardest in industrial metal. The reason why is different in hardness with the same metal is a difference of an orbit used for a metallic bond. The metal, which is affected by the non directionality S orbit, is hard to cut the metallic bond. Therefore such kind of metals show high tenacity by the transformation. On the other hand, the metal, which is affected by directionality P orbit, show low tenacity. Because big energy is necessary for the expansion and contraction by transformation. Tungsten Carbide, which obtain p orbit of carbon by increasing carbon as impurities, became harder than other metals including tungsten itself. 21
22 Tungsten Carbide Comparison to Stainless steel Hard metal properties Slot die lips for wear resistance Unit Tungsten Carbide SUS316L S31603 SUS304 S30400 Specific gravity Hardness Hv (max500) 150(max510) Thermal conductivity W/m* Thermal Expansion coffecient xe-6/ Young's Modulus Gpa Bending Strength GPa Computer analysis introduces a case study of lip wear for critical process control. This study helps in understanding geometric modeling of slot die lips and helps support the necessity of wear resistant material for slot die lips. Additionally this analysis shows the resulting cases of protection against corrosive fluids. 22
23 Comparison of grain size Tungsten Carbide for Slot Die Comparison to Stainless steel S31603(SUS316L) Ultra Micro Grain Series Micro Grain Series S30400(SUS304) 100um Hv um Hv um um
24 24
25 25
26 26
27 27
28 28
29 29 Computer Simulation and Fluid Analysis
30 30 Computer Simulation and Fluid Analysis
31 31 Computer Simulation and Fluid Analysis
32 32 Computer Simulation and Fluid Analysis
33 Super finish grinding of tungsten carbide Millar Face Super Polishing and High Precision Below Rz0.1μm 33
34 Super Polishing and High Precision Super finish grinding 34
35 Market Demand and Our Activities Slot Die Precision The results of the straightness (Example) 1 The slit surface (High precision 1600L ) Straightness 1 : 0.75μm Straightness 2 : 0.75μm Super Polishing and High Precision 1 2 Straightness 3 : 1.25μm 2 The slit surface (Normal precision 1500L) Straightness 1 : 2.25μm Straightness 2 : 2.50μm Straightness 3 : 2.25μm
36 36 Experiment and Evaluation In House Experiment is also used high precision machine.
37 Conclusion Precision stripe coating : direct groove type is suitable. Slit quality : Sharp edge, Smoothness, Straightness, reliable slit dimension Possible Benefit : Solve issues Hot spot issue on OPV Cross talk issue Conduction (Short) issue Tungsten carbide is outperform to Stainless steel to maintain precision stripes.
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