A simulation model to approximate penetration of a non-Newtonian fluid into a porous media during slot die coating

A computational fluid dynamics (CFD) model has been developed to predict the penetration depth of a non-Newtonian fluid as it is directly coated onto porous media by a slot die coating process. The model couples 1-D modified Blake–Kozeny equations and Navier–Stokes equations. Experiments of coating a non-Newtonian solution (black strap molasses) onto carbon paper (Toray 090) are conducted and the penetration depths are measured to validate the model. Preliminary results show that predicted and measured penetration depths follow the same trend; that is, as the coating speed increases the penetration depth decreases. However, the simulated penetration depths are found to be one to two times higher than measured values at low coating speeds. Even so, the results are considered reasonable, due to imposed simplifications and approximations of the CFD model and errors associated with the experiments and measurements.