Advanced Tape Coating Solutions for Manufacturing

The tape coating process is a technology that ensures uniform coating on the substrate and is widely applied across industries, including Tape manufacturing, paper, printing, electronics, and others. The whole process shall comprise Substrate preparation, coating systems (such as doctor blade and roller coating), curing systems (ovens), and transmission & rewinding systems.

At the first step, adhesives or other functional materials (such as inks or coatings) are applied onto substrates (such as BOPP films, paper, fabrics, or metal foils). We usually set a precise thickness to meet performance requirements; the next regular. Adhesive Coating steps are drying, curing, rewinding, and other processes until a tape product is well-manufactured. All our tapes can be adjusted at any step to ensure your customized tape specifications.

The core of the whole process is how we control the substrates and coat thickness to meet different Scenarios(home or industrial, etc.), functions (sealing, bonding, stripping, etc), and features(waterproof, heat resistant, electrical isolation, etc.),  and how we speed up drying production to improve production efficiency in case of shipment delay. This shall be no problem for the Egret Group, as we have automated product lines and advanced technology.

Coating Technology can be applied to nearly all types of tapes, including Aluminum Foil, PET, Foam, PE, Paper, Vinyl, Cloth, PP, Fiberglass, PO Film, and Polyimide.

Principle: Comma bar coating adjusts the gap between the blade and the substrate to control coating thickness, and it is usually paired with a backing roller. When it starts coating, adhesion, or other special coating liquid in the trough contacts the substrate surface, forming a wet film. Then the comma blade, which is usually made of a high-hardness alloy, scrapes off excess liquid, maintaining a wet film by adjusting the gap with the substrate (usually 10–500 μm).

Application Features: Often used for Medium-viscosity liquids (such as paints and adhesives), the coating speed can range from 1 to 50m/min, and the thickness can be customized from 10 to 500 μm by adjusting the Blade-substrate gap or applied pressure.

Pros: Simple structure, low equipment cost, easy to maintain, suitable for small-batch, multi-variety production.

Cons: Sensitive to liquid viscosity, needs a lower coating speed to avoid Non-uniform coating thickness, Bubbles or voids, Incomplete coating / stringing, Coater instability or vibration, Edge build-up (beading), Surface defects or striations

Principle: Slot die coating is a high-precision, non-contact coating technology in which the coating liquid is uniformly applied to substrates, creating a coating layer with a customizable thickness. The slot die coater contains a precision-machined slot with a width ranging from tens of micrometers to several millimeters. This coater usually uses a flow meter and a thickness sensor as its control system. Then our coating material can be transferred to the slot die coater and formed.

Application Features:  Slot Die Coating is mostly used for High-viscosity liquids (such as electrode slurry and optical adhesive). It can offer high-precision control: at any point on the same coated substrate, the coating thickness deviation will be within ±1%. The speed can reach 100m/min and is capable of multi-layer coating (such as double-sided coating of lithium-ion battery cathodes and anodes).

Pros:  High-precision process(thickness deviation within ±1% ), Non-Contacting coating process(Does no damage to substrates), Capable of multi-layer co-extrusion, Adapted to speed range 0.1-100m/min.

Cons: High-cost machine, high die machining complexity, and high risk of clogging. High-viscosity liquids also require high-pressure pumps, which increase energy consumption; the operation also requires experienced staff.