A New Method of Patterning Fluids onto Substrates using a Variable Lip Slot Die

This paper discusses the development of a new manufacturing technology, called a Variable Lip Slot Die (VLSD), used for automatically patterning viscous liquid materials (e.g., adhesives, sealants) in a controlled manner. This is not easily done due to the characteristic properties of these types of materials, i.e., high viscosity, temperature-dependent rheological properties, tendency to cure. A VLSD is essentially a standard slot die with a pinactuated variable lip that allows for real-time control over the pattern and thickness of viscous liquids deposited on a substrate. The advantages of the VLSD over other more conventional patterning methods (e.g., stenciling) include: versatility, flexibility, repeatability, accuracy, speed, little or no material waste, cost savings, and manufacturing control over the deposited liquid pattern.