Application Unit Air Discharge Hole for Viscous Material Pooling
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Solution Overview
Problem
Conventional systems using application needles face instability in applying high-viscosity electrically conductive materials over time due to material pooling, leading to non-uniform application and failure in repeated applications.
Innovation Solution
An application unit with a container and needle system featuring a third hole for air discharge, preventing material pooling by allowing air to escape when the needle inserts, thus maintaining a stable material flow and preventing hermetic sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If material application is repeated multiple times, then the application needle can apply material to multiple target objects, but application material adheres to the upper part of the application needle and enters the gap between the needle and wall of second hole to hermetically seal the upper lid, generating a pool of application material that causes non-uniform application
Solution Approach 1:
The patent extracts the air trapping problem from the sealed container system by introducing a third hole in the bottom wall of the container. This allows air to escape during needle insertion and material application, preventing the hermetic sealing that causes material pooling. The harmful air pocket is actively removed through the dedicated escape path, resolving the contradiction between repeated applications and application uniformity.
Solution Approach 2:
The third hole acts as an intermediary element between the container interior and exterior, facilitating air discharge. This intermediary structure enables the system to maintain both the sealed environment needed for material containment and the air escape path needed to prevent pooling, allowing repeated applications without compromising uniformity.
2Ease of operation
If the application needle is inserted into the application material container to apply material, then material can be transferred to the target object, but air in the container is pressurized pushing material out to form a pool
Solution Approach 1:
The patent removes the pressurized air from the container system by providing a dedicated escape path through the third hole. When the needle inserts and displaces air, the pressurized air can escape through the third hole rather than pushing material out to form pools. This extraction of the harmful pressurized air maintains both operational capability and application precision.
3Manufacturing precision
If the gap between the application needle and wall of second hole is small to enable fine material application, then precise material transfer is achieved, but the gap allows material to enter and hermetically seal the upper lid preventing air discharge
Solution Approach 1:
The patent segments the air discharge function from the material application function by creating a separate third hole dedicated to air escape. The second hole maintains its small dimensions for precise material application, while the third hole provides the air discharge pathway. This segmentation allows both functions to operate independently without interfering with each other, resolving the contradiction between precision and reliability.
Solution Approach 2:
The third hole serves as an intermediary structure that resolves the conflict between the small gap needed for precision and the air discharge needed for reliability. It provides a dedicated pathway for air to escape without interfering with the precise material application through the second hole, allowing both requirements to be satisfied simultaneously.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables stable and long-term application of high-viscosity materials, ensuring uniform application and preventing material pooling, which is particularly beneficial for drawing fine circuits like RFID tags.
Implementation Method 1
A third hole is formed in a part of the container for allowing air to be discharged through the third hole when the large-diameter shaft of the application needle is inserted in the application material container
Implementation Method 2
The application needle comprises an upper part having a large diameter shaft arranged to be inserted into the application material container. A fine gap is formed between the wall of the second hole and the application needle to enable the application needle to move up and down.
Data Source
Figure 1
Figure 2(A)~3(B)
Figure 4(A)~5
AI summary
An application unit (4) includes an application material container (21) to contain an application material, and an application needle (24) to apply, to a target surface, the application material contained in the application material container (21). A first hole (22) is formed in a bottom of the application material container (21), and a second hole (27) is formed in an upper lid (29) of the application material container (21). The application needle (24) is configured to be movable along a line passing through the first hole (22) and the second hole (27). A third hole (80) is formed in a part of the application material container (21) for allowing air to pass through the third hole, or a lowermost end of a wall of the first hole (22) has a chamfer (81, 82).