Coating Applicator Nozzle Angled Notch for Uniform Film
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Solution Overview
Problem
Conventional coating applicators face issues in applying a coating solution uniformly to rotating surfaces due to the accumulation of coating solution at the nozzle end, leading to irregularities and fragmentary bumps on the coated object, especially when using cylindrical nozzles with flattened ends.
Innovation Solution
A coating applicator with a cylindrical nozzle featuring an angled notch at the flattened end, where the rotation control unit positions the notch upstream from the application point, and a chamfer along the outside circumference to prevent solution accumulation, ensuring even application of the coating solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a cylindrical coating nozzle with a flattened end is used to apply coating solution, then the coating solution can be applied to a larger area, but the coating solution accumulates at the upstream portion of the nozzle end due to surface tension, forming bumps
Solution Approach 1:
The flattened end of the coating nozzle is segmented into multiple discharge orifices instead of a single continuous opening. This segmentation prevents the coating solution from accumulating at the upstream portion by providing multiple discrete discharge points, thereby eliminating the bump formation while maintaining adequate coating area coverage.
Solution Approach 2:
The nozzle end structure is modified with different local characteristics: multiple discharge orifices are positioned at specific locations including the upstream end, with varying orientations (some inclined relative to the nozzle axis). This local quality variation ensures uniform coating distribution by preventing accumulation at critical areas while maintaining overall coating effectiveness.
2Productivity
If the coating nozzle is moved in the radial direction of the rotating coating object, then the coating solution can be applied efficiently, but the coating thickness varies across the surface
Solution Approach 1:
The coating nozzle is designed with rotational capability and multiple discharge orifices oriented in different directions. During coating application, the nozzle rotates to dynamically adjust the discharge direction, ensuring that coating solution is evenly distributed across the rotating substrate surface. This dynamic adjustment compensates for the radial movement effect and maintains uniform coating thickness.
Solution Approach 2:
The problem of variable coating thickness due to radial movement is solved by introducing rotational movement as another dimension. The multiple orifices are arranged in three-dimensional space with different orientations, and the nozzle rotates to utilize these different spatial dimensions, thereby achieving uniform coating distribution across the surface despite radial traversal.
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 ensures a uniform coat thickness and prevents the formation of fragmentary bumps by effectively managing the coating solution's flow, ensuring consistent application across the rotating surface.
Implementation Method 1
Because of the effect of surface tension and the like, the shifted coating solution accumulates on the end of the coating nozzle 1, forming a bump upstream from the position to feed the coating solution 2 to the coating object 3.
Data Source
AI summary
A cylindrical coating nozzle having a flattened end is placed above a coating object being rotated. A coating solution is applied to a surface of the coating object by discharging the coating solution form a nozzle orifice at an end of the coating nozzle while moving the coating nozzle relative to the coating object in a direction intersecting a rotational direction of the coating object. The coating nozzle is formed with an angled notch at a part of the end thereof. A rotation control unit controls the rotation of the coating nozzle in a manner that the notch of the coating nozzle is positioned upstream from a position to feed the coating solution to the coating object being rotated.