Coating Module Shim Plate Segmentation for Uniform Liquid Distribution
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Solution Overview
Problem
Current coating devices for film-coating processes are costly due to the need for complex diversion structures and high surface smoothness requirements, leading to increased manufacturing and production costs, and limited reusability, as the restrictor surfaces wear out quickly.
Innovation Solution
A coating module with two plates and a diversion structure featuring a slot with a slot inlet and outlet, where the diversion structure includes a diversion inlet, channel, and manifold, allowing for adjustable flow and easy replacement of worn plates, reducing production costs and enhancing reusability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex diversion structures (T-die type, fishtail type, or coat-hanger type) are used to achieve uniform liquid distribution, then coating uniformity is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The coating device is divided into a reusable coating head and replaceable shim plates. The shim plates contain the diversion structures and restrictors, which are segmented as separate replaceable components. This allows the complex diversion structures to be optimized for coating uniformity while being easily replaced when worn, resolving the contradiction between achieving uniform coating and managing device complexity.
Solution Approach 2:
The coating head is designed as a universal platform that can accommodate multiple types of shim plates with different diversion structures (T-die type, fishtail type, coat-hanger type). This universal design allows the system to achieve different coating uniformity requirements by simply changing the shim plate, rather than designing entirely different coating devices for each application.
2Manufacturing precision
If high surface smoothness is achieved through lapping and polishing to ensure uniform liquid flow, then coating uniformity is improved, but manufacturing cost increases
Solution Approach 1:
The shim plates are designed as disposable or easily replaceable components rather than permanent parts requiring extensive finishing. By using materials that can be easily polished or replaced at low cost, the system achieves the necessary surface smoothness for uniform coating without incurring high manufacturing costs for permanent high-precision components.
Solution Approach 2:
The surface smoothness requirement is managed by changing the material parameters of the shim plates. Materials are selected that can achieve the required surface smoothness through simpler, less costly processing methods, or that can be easily reconditioned by polishing when worn, rather than requiring expensive initial machining and finishing of permanent components.
3Reliability
If the restrictor surface is worn, then replacement of the entire coating device is required, but this increases production cost and reduces reusability
Solution Approach 1:
The coating device is segmented into a permanent coating head and replaceable shim plates containing the restrictors. When the restrictor surface wears and coating quality deteriorates, only the inexpensive shim plate needs to be replaced, not the entire coating device. This dramatically reduces replacement cost and extends the overall system life.
Solution Approach 2:
The shim plates are designed to be discarded after a certain period of use when the restrictor surface wears out, rather than attempting to refurbish or replace the entire coating device. The reusable coating head is retained and can accommodate new shim plates, effectively recovering the valuable portion of the system while discarding only the worn consumable component.
4Manufacturing precision
If different diversion structures are designed for different coating liquid characteristics and methods, then coating performance is optimized, but device adaptability decreases
Solution Approach 1:
The coating head is designed as a universal platform that can accommodate multiple types of shim plates with different diversion structures (T-die type for certain liquids, fishtail type for others, coat-hanger type for different methods). This allows the system to optimize coating performance for different coating liquid characteristics and methods by simply changing the shim plate, rather than requiring different entire coating devices, thereby maintaining high adaptability.
Solution Approach 2:
The system transitions from a static, fixed design to a dynamic, configurable system where the shim plate can be changed based on the specific coating application requirements. This dynamic adaptability allows optimization of coating performance for different liquids and methods while reusing the same coating head infrastructure.
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 coating module achieves uniform liquid coating with lower production costs and improved reusability by allowing for easy plate replacement and adaptation to different coating processes without altering the entire device, thus reducing manufacturing expenses and maintaining coating quality.
Implementation Method 1
the liquid is configured to enter the diversion structure via the injecting port, then flow to the slot inlet through the diversion structure, then flow into the slot via the slot inlet
Implementation Method 2
then outflow from the slot via the slot outlet to be coated onto the substrate
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A coating module is suitable to coat a liquid onto a substrate and includes two plates and a diversion structure, in which there is a slot between the plates, and the slot has a slot inlet and a slot outlet, and one of the plates has an injecting port. The diversion structure makes the injecting port communicated with the slot inlet, in which the liquid is configured to enter the diversion structure via the injecting port, and flow to the slot inlet through the diversion structure, then flow into the slot via the slot inlet and then outflows from the slot via the slot outlet to be coated onto the substrate.