Inkjet Film Coating Layout for Uniform Particle-Layer Deposition
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Solution Overview
Problem
Existing film forming methods using inkjet heads to create multiple layers on a substrate face challenges in achieving uniformity, particularly when forming films on substrates with particle-based layers, leading to defects such as short circuits and reduced product quality.
Innovation Solution
The method involves using multiple inkjet heads arranged in a conveyance direction to apply ink to different locations on the substrate, allowing sufficient time for air replacement within particle-based layers, thereby preventing defects and enhancing film uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple inkjet heads discharge coating liquid in multiple stages to form multiple layers, then the coating process can be completed, but the film uniformity deteriorates due to air replacement issues in particle-based layers
Solution Approach 1:
The patent applies periodic action by implementing intermittent coating where coating heads alternate between coating and non-coating periods. During the non-coating period, air replacement in the particle-based layer occurs without liquid discharge interference. This periodic on-off coating pattern prevents round defects while maintaining productivity through multiple coating heads working in sequence.
Solution Approach 2:
The patent segments the coating process by dividing it into multiple stages with different coating heads operating at different positions. Each coating head covers a specific region and operates intermittently, allowing air replacement to occur in segments between coating operations. This segmentation prevents the formation of round defects while maintaining overall coating efficiency.
2Productivity
If coating liquid is discharged continuously to improve productivity, then coating speed increases, but film uniformity deteriorates due to insufficient air replacement time
Solution Approach 1:
The patent implements periodic action by creating intermittent coating cycles where each coating head operates for a coating period followed by a non-coating period. This allows air replacement to occur during the non-coating period while maintaining overall productivity through multiple heads working in parallel and sequence, thus achieving both speed and uniformity.
Solution Approach 2:
The patent applies preliminary action by ensuring air replacement occurs before subsequent coating operations. The non-coating period is strategically positioned to allow air replacement to complete before the next coating head begins operation, preventing round defects from forming while maintaining continuous production flow.
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 improves the uniformity of the film formed, reducing defects and ensuring higher quality by intermittently applying ink from each head to different locations, thus enhancing the reliability and performance of the final product.
Implementation Method 1
a coating step of coating a target coating material by discharging liquid from each of a plurality of discharge heads
Data Source
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AI summary
A film forming method for forming a film on a target coating material (102) includes a coating step of coating a target coating material by discharging liquid from each of a plurality of discharge heads (103 A- 103 D) that are arranged in a conveyance direction of the target coating material to be conveyed, wherein, in the coating step, the liquid discharged from each of the plurality of discharge heads is applied to a different location on the target coating material in the conveyance direction.