Die Coater Slot Uniformity via Fastener Torque
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Solution Overview
Problem
Existing die coating technologies face challenges in achieving uniformity of the coating layer thickness, particularly in applications requiring high precision, due to factors like non-uniform slot profiles and internal stresses in die blocks, which affect the distribution of pressure and flow of coating material.
Innovation Solution
The method involves adjusting the compression forces between die blocks using fasteners, employing an offset bracket, and utilizing shims with non-uniform thickness to achieve a uniform coating slot profile, thereby ensuring consistent coating thickness across the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If uniform compression force is applied to die blocks using fasteners, then assembly simplicity is maintained, but coating slot profile uniformity deteriorates due to internal stresses
Solution Approach 1:
The patent applies different compression forces to different fasteners based on their specific locations and roles in the die assembly. Front row fasteners receive different torque values than back row fasteners, and corner fasteners are adjusted independently. This local differentiation compensates for varying internal stresses and geometric configurations across the die block, achieving uniform coating slot profiles while maintaining operational simplicity through a systematic adjustment procedure.
2Device complexity
If standard fastener configuration is used, then device complexity is minimized, but coating thickness uniformity deteriorates
Solution Approach 1:
The patent introduces dynamic adjustability to the fastener configuration, allowing operators to modify fastener forces based on observed coating uniformity. The systematic adjustment procedure enables real-time optimization of coating thickness uniformity by adjusting individual fastener torque values, transforming a static fastener system into a dynamically可调 system that can compensate for manufacturing variations.
3Reliability
If compression force is increased to improve slot sealing, then coating material flow control improves, but slot profile uniformity deteriorates due to stress concentration
Solution Approach 1:
The patent systematically varies the compression force parameter across different fasteners rather than applying a uniform force. By adjusting the torque values of individual fasteners based on their positions (front row, back row, corners) and the specific coating requirements, the system achieves adequate sealing while maintaining slot profile uniformity. This parameter differentiation allows optimization of both sealing performance and profile consistency.
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
This approach enables the formation of a coating layer with a thickness uniformity of within ±20% for low-grade applications and ±0.5% for high-grade applications, significantly improving the precision and consistency of the coating layer.
Implementation Method 1
each of the plurality of fasteners provides a compression force between the first die block and the second die block
Data Source
AI summary
A method for forming a coating layer is provided according to the invention. The method includes steps of assembling a die coater comprising a first die block (12), a second die block (14), and a plurality of fasteners (40) holding the first die block and the second die block together, wherein each of the plurality of fasteners provides a compression force between the first die block and the second die block, and the first die block and the second die block are constructed to provide an internal manifold (16) and a coating slot (18), and extruding a coating material through the internal manifold and the coating slot. The coating slot can be adjusted to provide a more uniform coating slot along the length of the coating slot by adjusting the compression force of the fasteners, utilizing an offset bracket (80), adjusting the die bolt locations, adjusting the die overhang, providing a non-uniform shim (30), or a combination thereof. A die coater is additionally described.