Contact-Angle-Guided Semi-Cured Slot-Die Coating Eliminates Air Entrapment in LED Multilayer Films

LED polymer multilayer films offer clear advantages over single-layer coatings, such as minimized particle settling, finer control over particle distribution, and more precise spectral tuning. However, the standard "coat-dry-coat" process for these multilayer systems often traps air bubbles, degrading film quality and uniformity. This study investigates the air entrainment mechanism in multilayer film formation. Bubbles form when the cured bottom layer exhibits a low contact angle, which destabilizes the advancing liquid front. High-speed microscopy captured these interfacial dynamics, and contact-angle measurements quantified the wetting behavior. Numerical simulations further demonstrated that reduced wettability and vortex formation drive air entrainment. To mitigate air entrainment, a semi-cured slot die coating approach was proposed to modify the surface wettability and suppress the flow instabilities. Incorporating temperature-dependent viscosity into the simulation model improved its predictive accuracy, cutting the error in predicted coating-gap limits from 11.49% to 4.99%. This combined strategy delivers reliable, bubble-free multilayer films and paves the way for more consistent, high-quality LED polymer applications.