Die Head Impurity Removal via Internal Space

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Solution Overview

Problem

Existing laminated body forming apparatuses face challenges in achieving uniform thickness and preventing impurity failures in coating films due to bubble presence, often requiring dedicated bubble removal devices that increase complexity, cost, and reduce productivity.

Innovation Solution

A laminated body forming apparatus with multiple die head units, each comprising a front blade, center blade, and rear blade, where the internal impurity removal space between the center and rear blades allows bubbles to float and escape, ensuring a uniform coating film thickness without a dedicated bubble removal device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a dedicated bubble removal device is used to remove bubbles from slurry, then impurity removal effectiveness is improved, but device complexity increases and productivity decreases

Engineering Contradiction:

Improveimpurity removal effectivenessVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the coating application function and bubble removal function into a single die head apparatus. The internal impurity removal space is integrated within the die head structure, allowing bubbles to be removed during the coating process itself, eliminating the need for a separate dedicated bubble removal device.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The die head apparatus performs multiple functions: it applies slurry to the substrate and simultaneously removes bubbles through the internal impurity removal space. This multi-functional design replaces what would traditionally require separate dedicated devices for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a dedicated bubble removal device is used to remove bubbles from slurry, then impurity removal effectiveness is improved, but productivity decreases due to increased process steps

Engineering Contradiction:

Improveimpurity removal effectivenessVSAvoidproductivity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Bubbles are removed in advance during the coating application process itself, before the coating film is fully formed and transferred to subsequent processing stages. The internal impurity removal space enables preliminary bubble removal as part of the coating process.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If multiple die head apparatuses are arranged in series, then coating film uniformity is improved, but device complexity increases

Engineering Contradiction:

Improvecoating film uniformityVSAvoiddevice complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent divides the coating process into multiple stages by arranging several die head apparatuses in series. Each die head independently applies coating and removes bubbles, with the cumulative effect producing highly uniform coating films. The segmentation of the coating process into multiple passes achieves precision that would be difficult with a single apparatus.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each die head apparatus in the series performs the same multi-functional role of applying slurry and removing bubbles simultaneously. This repetition of universal functional units achieves cumulative precision improvement while maintaining consistent design principles across all apparatuses.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 apparatus effectively removes impurities and achieves uniform thickness in coating films by utilizing internal and external impurity removal spaces, enhancing productivity and reducing costs by eliminating the need for a dedicated bubble removal device.

Implementation Method 1

the impurities contained in the coating film are removed by floating to the surface of the coating film and escaping

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Data Source

PatentEP3597308B1Die head device, application method, and laminate forming device

Publication Date: 2023.03.15 NISSAN MOTOR CO LTD

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AI summary

[Problem] To provide a coating method and a die head apparatus that can form coating films of uniform thickness without impurity failures and without a dedicated device for the removal of impurities, and a laminated body forming apparatus that can form a laminated body of the coating films. [Solution] A die head apparatus comprises a front blade 130A, a rear blade 160A, a center blade 140A, and an internal impurity removal space 150A. The front blade 130A and the center blade 140A are configured to form a pool of a slurry SA. The internal impurity removal space 150A is positioned between the center blade 140A and the rear blade 160A. A distance D4A separating the rear blade 160A and the substrate 80 is set to be smaller than the distance D1A separating the center blade 140A and the substrate 80.