Ultrathin Fluorine Film Scale for Encoder Corrosion
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Solution Overview
Problem
Existing scales used in encoders suffer from corrosion and measurement accuracy issues due to environmental factors like humidity and temperature, and conventional protective coatings either fail to prevent corrosion or cause diffused reflection leading to reduced accuracy.
Innovation Solution
A scale design featuring a base material with metal or transparent scale patterns coated with a monomolecular fluorine film and a chemically stable transparent dielectric protection film, which inhibits corrosion and maintains measurement accuracy by preventing water accumulation and reducing friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the scale patterns are covered with an inorganic material, then corrosion resistance is improved, but measurement accuracy deteriorates due to diffused reflection
Solution Approach 1:
The patent applies a fluorine resin film that is extremely thin (5-30 nm) to cover the scale patterns. This thin film provides corrosion protection while being transparent to light, preventing diffused reflection that would occur with thicker coatings. The film acts as a protective shell that maintains optical clarity.
Solution Approach 2:
The patent changes the thickness parameter of the protective coating to an extremely small range (5-30 nm), which is sufficient to provide corrosion resistance but thin enough to allow light to pass through without significant diffused reflection, thereby maintaining measurement accuracy.
2Reliability
If a thick fluorine resin film is used to prevent corrosion, then corrosion resistance is improved, but measurement accuracy deteriorates due to scratches and diffused reflection
Solution Approach 1:
The patent dramatically reduces the film thickness parameter from conventional thick coatings to an ultrathin range of 5-30 nm. This parameter change allows the film to provide adequate corrosion protection while eliminating the problems of scratches and diffused reflection that occur with thicker films.
Solution Approach 2:
The patent employs an ultrathin fluorine resin film (30 nm or less) that forms a flexible protective layer on the scale patterns. This thin film configuration provides corrosion resistance without the mechanical issues and optical interference problems associated with thicker coatings.
3Measurement precision
If the scale patterns are left uncovered, then measurement accuracy is maintained, but corrosion resistance deteriorates
Solution Approach 1:
The patent applies an ultrathin fluorine resin film (5-30 nm) that serves as a protective shell against corrosion while maintaining optical transparency. This thin film configuration ensures that light transmission is not significantly affected, preserving measurement accuracy while providing necessary corrosion protection.
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 solution effectively prevents corrosion and maintains high measurement accuracy even in harsh environments, while minimizing the risk of diffused reflection and ensuring smooth encoder operation.
Implementation Method 1
a fluorine film that covers the scale patterns and is at least partly a monomolecular fluorine compound
Implementation Method 2
a chemically stable transparent dielectric protection film, which inhibits corrosion and maintains measurement accuracy by preventing water accumulation and reducing friction
Data Source
AI summary
A scale includes a base material, scale patterns arranged at a predetermined periodicity on a main surface of the base material, and a fluorine film that covers the scale patterns and is at least partly a monomolecular fluorine compound.