High-Filler Coating Process for Uniform Insulating Layers
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Solution Overview
Problem
Conventional coating methods struggle with unevenness and thickness variation in coating films when forming insulating layers with increased filler content, hindering mass production and uniform contact with substrates.
Innovation Solution
A coating method using a specific coating apparatus with a conveying roller, knife coater, and liquid-reserving member, optimized parameters such as roller and coater diameters, and controlled viscosity to suppress unevenness and thickness variation in coating films with high filler content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the content ratio of filler in coating liquid is increased to improve thermal conductivity, then heat dissipation performance is improved, but coating film unevenness and thickness variation increase
Solution Approach 1:
The patent applies parameter changes by optimizing the filler content ratio (65-95 parts by mass per 100 parts by mass of resin+filler), coating liquid viscosity (100-20000 cP at 25°C), and coating apparatus parameters (conveying roller outer diameter 50-270 mm, knife coater outer diameter 50-170 mm, gap distance 1-120 mm). These parameter optimizations enable high filler content coating liquids to produce uniform coating films with controlled thickness variation, resolving the contradiction between heat dissipation performance and coating uniformity.
2Temperature
If the content ratio of filler in coating liquid is increased to improve thermal conductivity, then heat dissipation performance is improved, but coating film appearance unevenness worsens
Solution Approach 1:
The patent optimizes multiple parameters including filler content ratio (65-95 parts), coating liquid viscosity (100-20000 cP), and coating apparatus geometry (conveying roller diameter 50-270 mm, knife coater diameter 50-170 mm, gap 1-120 mm). These parameter changes ensure uniform coating film appearance even with high filler content, eliminating surface unevenness while maintaining heat dissipation performance.
3Temperature
If conventional coating methods are used with high filler content coating liquid, then heat dissipation performance is improved, but mass production capability deteriorates
Solution Approach 1:
The patent establishes specific parameter ranges (filler content 65-95 parts, viscosity 100-20000 cP, roller diameter 50-270 mm, knife coater diameter 50-170 mm, gap 1-120 mm) that enable conventional coating apparatuses to efficiently produce uniform coating films with high filler content. These parameters allow mass production while maintaining both heat dissipation performance and coating quality.
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 method effectively reduces coating film unevenness and thickness variation, enabling high thermal conductivity and uniform coating films suitable for insulating layers.
Implementation Method 1
a conveying roller that feeds a substrate
Implementation Method 2
a knife coater that is disposed above the conveying roller with a gap from the conveying roller, has a columnar or cylindrical shape, and is provided with a knife portion
Implementation Method 3
form a coating film of a coating liquid stored by the liquid-reserving member on a surface of the substrate
Data Source
AI summary
A coating method including: using a coating apparatus including a conveying roller that feeds a substrate; a knife coater that is provided with a knife portion; and a liquid-reserving member having a one end portion positioned on a side of the conveying roller and partitioning a liquid-reserving space together with the conveying roller, wherein the coating liquid contains a resin, a solvent, and a filler, and the filler is contained in a content ratio of 65 to 95 parts by mass with respect to 100 parts by mass of a mixture of the resin and the filler, an outer diameter D1 of the conveying roller is 50 to 270 mm, an outer diameter D2 of the knife coater is 50 to 170 mm, and a distance D3 from the gap to the one end portion is 1 to 120 mm.