Abstract
A novel idea was proposed to the design of a coating die for delivering suspensions. In addition to considering the lateral flow uniformity of the liquid sheet, particle sedimentation is also avoided by maintaining high shear rates inside the die. Only two shims are designed to deliver the coating suspensions, and these two shims are easy to make and flexible for replacement. Two theoretical tools were developed for die design, i.e., one-dimensional lubrication approximation combined with the optimal design and three-dimensional finite element simulation. The coating suspension was assumed to obey the Bingham model. It was found that the one-dimensional lubrication approximation can offer the basic optimal design, whereas edge effects can be minimized through three-dimensional finite element corrections. Three experimental dies were built: a T-die, a fishtail die and a coat hanger die based on the optimal design. Experimental results verified the theoretical predictions. © 2012 Curtin University of Technology and John Wiley & Sons, Ltd.
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