Model for the outer cavity of a dual‐cavity die with parameters determined by two‐dimensional finite‐element analysis

A coating die forms liquid layers of uniform thickness for application to a substrate. In a dual‐cavity coating die an outer cavity and slot improves flow distribution from an inner cavity and slot. A model for axial flow in the outer cavity must consider the ever‐present cross flow. A 1‐D equation for the pressure gradient for a power‐law liquid is obtained as a small departure from a uniform flow distribution and no axial flow. The equation contains a shape factor dependent on cavity shape, Reynolds number, and power‐law index. The shape factor for five triangular cavity shapes is obtained by finite‐element analysis and correlated for application to die design up to the onset of flow recirculation which arises at the junction of the cavity and outer slot. The performance of the combined cavity and slot is considered and the most effective design determined. © 2017 American Institute of Chemical Engineers AIChE J , 64: 708–716, 2018