ADVANCES IN SLOT DIE COATING

TECHNOLOGY FOR HOT MELT ADHESIVES

INTRODUCTION

• Hot melt adhesive coating

• Extrusion coating
• Liquid coating
INTRODUCTION

• Internal similarities
• External variations

• Hot Melt
o Versus Extrusion
o Versus Liquid
INTRODUCTION

• Internal similarities
Slot gap

• Hot Melt
Feed
o Versus Extrusion port

o Versus Liquid Distribution

chamber
Lip land
INTRODUCTION

• External variations
o Coating technique
• Hot Melt
o Versus Extrusion
o Versus Liquid
INTRODUCTION

• External variations
o Heat effect
• Hot Melt
o Versus Extrusion
o Versus Liquid
ADHESIVE RHEOLOGY
(VISCOSITY & ELASTICITY)
• Viscosity (shear rate versus viscosity)
• Elasticity (stress and velocity interaction)
ADHESIVE RHEOLOGY
(VISCOSITY & ELASTICITY)
• Defects
o Wrinkle
o Curl
o Voids
o Die Swell
o Edge Beads
ADHESIVE RHEOLOGY
(VISCOSITY & ELASTICITY)
• Solutions
o Wrinkle/Curl = reduce stress
at coating or during curing
o Voids = limit of process
o Die Swell = reduce internal
stress
o Edge bead = slot to
substrate gap
EQUIPMENT DESIGN

• 3D FEA
EQUIPMENT DESIGN
• System influence
o Slot die
o Positioner
o Roll
o Fluid delivery
 Adhesive formualtion
o Substrate
 Web handling/tension
OPERATION

• Variables
o Lip gap
o Lip offset
o Lip geometry
o Attack angle
o Die to substrate gap
OPERATION

• Limitations
o Line speed
 3280 feet/min (1000 meters/min)
o Coat weight
1 mil (25.4 microns)*
OPERATION

• Slot die design

o Flex lip
 >3 mils (76.2 microns)
o Rotary rod lip
 1-3 mils (25.4-76.2 microns)
OPERATION

• Slot die design

o Flex lip
 >3 mils (76.2 microns)
OPERATION

• Slot die design

o Rotary rod lip

 1-3 mils (25.4-76.2 microns)
OPERATION
• Roll interaction
o TIR < 0.0005 in (12.7 micron)
o Concentricity < 0.0005 in (12.7 micron)
o Cylindricity < 0.001 in (25 micron)
o Ra < 4 micro-in (0.1 micro-m)
o Durometer (90 Shore A)

o Rotary rod lip

 1-3 mils (25.4-76.2 microns)
CONCLUSION

• Hot melt coating = crossroads of technology

• Viscoelasticity
• Temperature effects
• System influence