Breaking through technical bottlenecks: Promoting the advancement of coating die heads

Whether it is a mobile phone, computer, electric car, or smart wearable device, products such as display optical film, lithium-ion battery electrode, car cover film, water treatment film, folding screen OCA optical glue, etc., are inseparable from the support of coating technology. As a key equipment, the optimization of the design, materials and manufacturing process of the coating die head directly affects the breakthrough of domestic substitution technology and is also related to the final product experience.

01 Core Challenges and Technical Requirements

In the application of coating technology, the die head faces many technical challenges, especially in terms of precision, production efficiency and adaptability. The following are several key technical challenges:

Challenges of low viscosity thin coating and high viscosity and high solid thick coating

During the coating process, the viscosity of the slurry varies greatly, from low viscosity thin coating (such as 1-5OCPS perovskite coating) to high viscosity and high solid content thick coating (more than 5OOOOCPS). According to different material characteristics, the die head needs to be optimized to ensure the uniformity and stability of the coating process and avoid irregularities during coating.

Requirements for high-precision coating

In optical films, semiconductor packaging and other application scenarios, the coating accuracy requirements are as high as nanometers, which puts high standards on every detail of the production process, especially in controlling the coating thickness and quality.

Complexity of multi-layer coating

In the multi-layer coating process, it is very important to accurately control the amount of each layer of coating to ensure that the final coating thickness and quality fully meet the design requirements. This places extremely high demands on the design, processing accuracy and assembly process of the die head.

 

 

 

 

 

 

 

 

 

 

 

Challenges of wide-width coating

When coating a large area, how to avoid uneven coating or other quality problems is always a challenge. The design of the die head must provide high precision and ensure sufficient production capacity to adapt to a wider range of production needs.

 

 

 

 

 

 

 

 

 

 

 

 

02 Breakthrough solution

In order to meet the above technical challenges, JCTIMES Times has proposed an efficient, accurate and stable coating die head solution through continuous technological innovation. The details are as follows:

2.5D analysis algorithm

JCTIMES, in collaboration with leading Japanese research in- stitutions, has developed a 2.5D analysis algorithm. By accu- rately analyzing both low-viscosity and high-viscosity slurries, this algorithm optimizes flow channel design and calculates the most reasonable flow parameters, thereby enhancing precision control during the coating process and ensuring high efficiency and stability in production.

Liquid bead morphology analysis

The coating droplet morphology analysis software can ac- curately simulate and calculate the coating process based on various factors such as die lip parameters, coating spac- ing, and slurry viscosity. This ensures that process require- ments are met, thereby improving coating uniformity and stability. Through this analysis, JCTIMES provides customers with systematic debugging solutions to further optimize pro- duction workflows.

Multi-layer application case

To meet the demands of multi-layer coating, JCTIMES has launched coating dies suitable for three-layer structures, in- cluding car wrap films, lithium battery coatings, and OCA coatings. The successful application of these technologies has significantly increased production line capacity and effi- ciency, effectively addressing the complex coating require- ments of three-layer structures.

High precision and corrosion resistance

JCTIMES coating die heads are made of imported high-performance steel to meet the needs of high precision, corrosion resistance and wear resistance. The maximum width of the die head can reach 40OOmm, with extremely high straightness and surface accuracy, and the cavity roughness can reach RaO.O2um. Such technical advantages ensure that the die head can still maintain high precision and stability under harsh working conditions.

The market’s demands for coating precision, film quality, and production efficiency are continuously increasing. JCTIMES will continue to dedicate itself to innovation in the die field, working hand in hand with industry partners to overcome critical technological bottlenecks, drive ongoing process innovations, and promote industrial upgrading.