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Volume 115
Internal die flows of concentrated suspensions in slot coating processes considering shear-induced particle migration
Min-Kyu Kim a, Hyun Wook Jung a b *
a Department of Battery-Smart Factory, Korea University, Seoul, 02841, Republic of Korea
b Department of Chemical and Biological Engineering, Korea University, Seoul, 02841, Republic of Korea
10.1016/j.partic.2026.05.009
Volume 115,
August 2026,
Pages 106-117
Received 17 February 2026, Revised 4 May 2026, Accepted 12 May 2026, Available online 19 May 2026, Version of Record 27 May 2026.
E-mail:
hwjung@grtrkr.korea.ac.kr
Highlights
• Shear-induced particle migration in concentrated suspensions markedly affects flow and particle distributions in slot dies.
• Particle nonuniformity at the feed inlet governs flow development in the chamber and slit.
• Particle distribution at the slit entrance controls widthwise advection and velocity profiles in the slit.
• Nonuniform inlet concentrations lead to exit-flow undulations and uneven wet thickness, including striped defects.
Abstract
Shear-induced particle migration in the internal die flows of concentrated particulate suspensions during slot coating processes was investigated using a diffusive flux model implemented within three-dimensional computational fluid dynamics simulations. Comparative simulations demonstrated that particle migration markedly altered the internal flow characteristics and particle distributions inside the slot dies. Inhomogeneous particle distributions at the feed inlet were found to modify the flow behavior in the chamber region and profoundly affect the velocity and particle concentration fields in the slit region. These changes critically influenced the die exit velocity and concentration profiles, which governed the uniformity of the wet coating thickness. The insights obtained from this study offer practical guidance for die design and process control to achieve a uniform coating thickness and stable slot coating operation.
Graphical abstract
Keywords
Slot coating; Internal die flow; Shear-induced particle migration; Concentrated suspension; Diffusive flux model
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