Coater Machine Automatic Foreign Matter Cleaning
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Solution Overview
Problem
In the flat panel display industry, particularly in TFT-LCD and AM-OLED manufacturing, manual shutdown and cleaning of coater machines due to surface pollution lead to inefficiencies and risks, causing coating defects like Mura, which significantly impact utilization rates and pose safety hazards.
Innovation Solution
A coater machine equipped with a movable first cleaner device, such as a brusher, air jetter, or water washer, and a detector system that automatically detects and removes foreign matter from the working surface, reducing the need for manual intervention and minimizing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual cleaning is performed when foreign matter is detected on the working surface, then coating quality is maintained, but production downtime increases and utilization rate decreases
Solution Approach 1:
The cleaning device is equipped with automatic detection and control systems that enable it to autonomously identify foreign matter on the working surface and execute cleaning operations without manual intervention. The system self-activates when contamination is detected, maintaining coating quality while minimizing production interruptions.
Solution Approach 2:
Manual cleaning operations are replaced by an automated mechanical cleaning device that can be rapidly deployed and operated. This substitution eliminates the time-consuming nature of manual cleaning while maintaining or improving cleaning effectiveness, thus preserving both coating quality and production efficiency.
2Object-generated harmful factors
If manual cleaning operations are performed, then foreign matter is removed from the working surface, but safety risks increase due to operator exposure to chemicals and machinery
Solution Approach 1:
The cleaning system operates autonomously without requiring operator presence in the hazardous environment. The automated device performs all cleaning functions, completely eliminating exposure risks to operators while effectively removing foreign matter from the working surface.
Solution Approach 2:
The automated cleaning device serves as an intermediary between the foreign matter on the working surface and the cleaning agents. It applies cleaning materials and performs removal operations without direct human contact, acting as a protective barrier that eliminates safety risks while achieving the cleaning objective.
3Manufacturing precision
If frequent manual inspections and cleaning are conducted, then coating defects are prevented, but overall system complexity increases
Solution Approach 1:
The detection system and cleaning device are merged into a single integrated unit. The detection function identifies foreign matter, and the cleaning mechanism responds automatically, combining what would otherwise be separate operations into one unified system. This integration prevents defects while managing complexity through functional consolidation.
Solution Approach 2:
The cleaning device is designed with multi-functionality, incorporating both detection and cleaning capabilities in one unit. This universal design eliminates the need for separate inspection and cleaning equipment, preventing coating defects while avoiding the complexity increase that would result from multiple independent systems.
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
The solution enhances cleaning efficiency, reduces utilization rate losses, and eliminates safety risks by automating the cleaning process, ensuring high cleanliness and preventing secondary pollution during the coating process.
Implementation Method 1
the first cleaner device is a brusher device, an air jetter device or a water washer device
Implementation Method 2
the first cleaner device is a brusher device, an air jetter device or a water washer device
Implementation Method 3
the brusher device comprises a cleaning roller, and the cleaning roller comprises a cleaning surface made of a cloth material
Implementation Method 4
the brusher device comprises a cleaning roller
Data Source
AI summary
A coater machine, a coater system and a cleaning method of the coater machine are provided. The coater machine includes: a coating platform including a working surface; and a first cleaner device configured to move relative to the working surface to remove a foreign matter on the working surface.