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.