Coating Head Oscillation to Mask Nozzle Clogging Streaks
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Solution Overview
Problem
Conventional coating devices using the inkjet method face challenges in maintaining consistent coating quality due to clogging of discharge holes, leading to visible streaks and uneven coating, especially when the gap between discharge drops increases.
Innovation Solution
A coating device with a head that vibrates or rotationally oscillates along the nozzle surface while moving in a controlled manner to intersecting directions, ensuring the nozzle surface and to-be-coated object face each other, effectively covering clogged discharge holes and improving coating quality by adjusting spatial displacement and vibration/oscillation periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the gap between discharge drops increases, then coating speed can be increased, but coating quality deteriorates due to visible streaks and uneven coating
Solution Approach 1:
The head is vibrated in a direction intersecting the movement direction, causing discharge drops to deviate from straight-line trajectories and fill gaps between drops, thereby maintaining coating quality at higher speeds
Solution Approach 2:
The head undergoes periodic vibration at specific frequencies, creating regular patterns of drop dispersion that ensure uniform coating coverage while maintaining high coating speed
2Reliability
If discharge holes become clogged, then coating reliability deteriorates, but increasing vibration amplitude may cause coating unevenness
Solution Approach 1:
Vibration of the head in an intersecting direction causes discharge drops to deviate and cover areas that would otherwise be missed due to clogged holes, maintaining coating reliability without excessive amplitude
Solution Approach 2:
The vibration parameters (amplitude, frequency, direction) are optimized to achieve the minimum effective deviation needed to cover clogged areas, preventing coating unevenness while maintaining reliability
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 controlled movement of the head ensures that discharge drops fill gaps caused by clogging, resulting in improved coating quality with reduced visibility of streaks and enhanced film smoothness, maintaining high resolution and surface area coating speed.
Implementation Method 1
The controller vibrates the head in a second direction intersecting a first direction, and/or rotationally oscillates the head along the nozzle surface
Implementation Method 2
rotationally oscillates the head along the nozzle surface while moving the head in the first direction along the nozzle surface
Data Source
AI summary
A coating device includes a head, an arm, and a controller. The head includes a nozzle surface. The arm holds the head. The controller controls movement of the head via the arm. The controller vibrates the head in a second direction intersecting a first direction, and/or rotationally oscillates along a nozzle surface while moving the head in the first direction along the nozzle surface in a state where the nozzle surface and a to-be-coated object face each other.