无论是手机、电脑，还是电动汽车、智能穿戴设备，像显示器光学膜、锂离子电池电极、车衣膜、水处理膜、折叠屏OCA光学胶等产品，都离不开涂布技术支持。涂布模头作为关键设备，其设计、材料和制造工艺的优化，直接影响着国产替代技术突破，也关系到最终产品体验。
Whether in smartphones, computers, electric vehicles, or wearable devices, the manufacturing of critical components such as display optical films, lithium-ion battery electrodes, paint protection films, water treatment membranes, and foldable OCA optical adhesives all rely on advanced coating technology. As a key piece of equipment, the coating die’s design, material selection, and manufacturing precision are vital to breakthroughs in domestic substitution and play a crucial role in determining final product performance and user experience.
核心挑战与技术需求
Key Challenges & Technical Requirements
在涂布技术的应用中，模头面临着众多技术挑战，尤其在精度、生产效率和适应性方面要求不断提升。以下是几个关键技术挑战：
In the application of coating technology, dies face numerous technical challenges, particularly with the increasing demands for precision, production efficiency, and adaptability. The following are several key technical challenges:
1. 低粘薄涂与高粘高固厚涂挑战
Challenges of low-viscosity thin coating and high-viscosity, high-solids thick coating.
在涂布过程中，浆料的粘度存在着很大的差异，从低粘度薄涂（如1-50CPS的钙钛矿涂层）到高粘度高固含量的厚涂（超过50000CPS），针对不同材料特性，模头需要进行优化设计，确保涂布过程中的均匀性与稳定性，避免涂布时出现不规则现象。
During the coating process, slurry viscosity can vary greatly — ranging from low-viscosity thin coatings (such as 1–50 CPS perovskite layers) to high-viscosity, high-solids thick coatings (exceeding 50,000 CPS). To accommodate the distinct properties of different materials, the die must be optimally designed to ensure uniformity and stability throughout the coating process, preventing irregularities or defects during application.
2.高精度涂膜的要求
Requirements for High-Precision Coating
在光学膜、半导体封装等应用场景，涂膜精度要求高达纳米级，这对生产工艺的每个细节提出了高标准要求，尤其是在控制涂膜厚度和质量方面。
In applications such as optical films and semiconductor packaging, coating precision demands can reach the nanometer level. This imposes extremely high standards on every detail of the production process, particularly in controlling coating thickness and quality.
3.多层涂布的复杂性
Complexity of Multi-Layer Coating
多层涂布过程中，精确控制每一层涂布的量至关重要，以确保最终的涂膜厚度和质量完全符合设计要求。这对模头的设计、加工精度和装配工艺提出了极高的要求。
In multi-layer coating processes, it is crucial to precisely control the coating amount of each individual layer to ensure that the final film thickness and quality fully meet design specifications. This places extremely high demands on die design, machining accuracy, and assembly craftsmanship.
4.宽幅涂布的挑战
Challenges of Wide-Web Coating
在进行大面积涂布时，如何避免涂层不均或出现其他质量问题，始终是一个挑战。模头的设计必须既能提供高精度，又能保证足够的生产能力，适应更广泛的生产需求。
When performing large-area coating, preventing coating non-uniformity or other quality issues remains a constant challenge. The die must be designed to deliver both high precision and sufficient production capacity to meet broader manufacturing demands.
突破解决方案
为了应对上述技术挑战，精诚时代通过持续的技术创新，提出了高效、精准、稳定的涂布模头解决方案。具体如下：
Breakthrough Solutions
To address the above technical challenges, JCTIMES has continuously advanced its technological innovation and developed efficient, precise, and stable die solutions. The key approaches include:
2.5D解析算法
2.5D Analysis Algorithm
精诚与日本顶尖研究机构合作，研发了2.5D解析算法，通过精确分析低粘度及高粘度浆料，优化流道设计，计算出最合理的流动参数，进而提升涂布过程中的精度控制，确保生产过程高效稳定。
JCTIMES, in collaboration with leading Japanese research institutions, has developed a 2.5D analysis algorithm. By accurately analyzing both low-viscosity and high-viscosity slurries, this algorithm optimizes flow channel design and calculates the most reasonable flow parameters, thereby enhancing precision control during the coating process and ensuring high efficiency and stability in production.
液珠形态分析
Droplet Morphology Analysis
涂布液珠形态分析软件能够根据不同模口参数、涂布间距和浆料粘度等因素，精准模拟计算涂布过程，确保工艺要求得以满足，从而提高涂布均匀性与稳定性。通过这一分析，精诚为客户提供了系统化的调试方案，进一步优化生产流程。
The coating droplet morphology analysis software can accurately simulate and calculate the coating process based on various factors such as die lip parameters, coating spacing, and slurry viscosity. This ensures that process requirements are met, thereby improving coating uniformity and stability. Through this analysis, JCTIMES provides customers with systematic debugging solutions to further optimize production workflows.
多层应用案例
Multi-layer Application Cases
针对多层涂布需求，精诚推出了适用于三层结构的车衣膜涂布模头、锂电涂布模头以及OCA涂布模头等。这些技术的成功应用，极大地提升了生产线的产能和效率，满足了三层结构等复杂涂布需求。
To meet the demands of multi-layer coating, JCTIMES has launched coating dies suitable for three-layer structures, including car wrap films, lithium battery coatings, and OCA coatings. The successful application of these technologies has significantly increased production line capacity and efficiency, effectively addressing the complex coating requirements of three-layer structures.
高精度与耐腐性
High Precision and Corrosion Resistance
精诚涂布模头采用进口高性能钢材制造，以满足高精度、耐腐蚀、耐磨损的需求。模头的最大宽幅可达到4000mm，具备极高的直线度和表面精度，腔体粗糙度可达Ra0.02um。这样的技术优势确保了模头在严苛工作条件下仍能保持高精度和稳定性。
JCTIMES coating dies are manufactured using imported high-performance steel to meet the demands for high precision, corrosion resistance, and wear resistance. The dies can reach a maximum width of up to 4000mm, featuring exceptional straightness and surface accuracy, with cavity roughness as low as Ra0.02μm. These technical advantages ensure that the dies maintain high precision and stability even under harsh working conditions.
市场对涂布精度、涂膜质量和生产效率的要求不断提高。精诚时代将继续致力于模头领域的创新，与行业同仁携手推动“卡脖子”技术突破，推动工艺持续创新和产业升级。
The market’s demands for coating precision, film quality, and production efficiency are continuously increasing. JCTIMES will continue to dedicate itself to innovation in the die field, working hand in hand with industry partners to overcome critical technological bottlenecks, drive ongoing process innovations, and promote industrial upgrading.
更多技术交流和探讨，欢迎现场莅临精诚展台：
For more technical exchange and discussions, you are warmly welcome to visit the JCTIMES booth on-site:
Ø 6月4-6日，第十七届上海国际水展（8.1H630）
Ø 6月11-13日，SNEC第十八届国际太阳能光伏与智慧能源展（1.1H-B230）
Ø 6月18-20日，FCVC第八届国际氢能与燃料电池汽车大会暨展览会（C19）
Ø 6月17-19日，APFE上海国际胶带与薄膜展（6T-035）
