Inkjet Line Head Nozzle Arrangement for Thin Film Coating
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Solution Overview
Problem
The existing thin film production methods using slit coaters are inefficient due to the need to change slit shapes for different patterns, leading to lowered operation and production efficiency.
Innovation Solution
A method involving an ink jet technique where a support is conveyed through a line head group with multiple nozzle heads arranged orthogonally, allowing for continuous coating and uniform thin film formation with adjustable nozzle hole arrangements to achieve desired patterns and thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a slit coater is used to form thin films with different patterns, then the desired pattern can be achieved, but the operation efficiency and production efficiency are lowered due to the need to replace slit shapes
Solution Approach 1:
The single slit coater is segmented into multiple line heads (first to M-th line heads), each equipped with nozzle holes that can be independently controlled. This segmentation allows different regions to form different patterns simultaneously, eliminating the need to replace slits for pattern changes while maintaining high production efficiency through parallel processing
Solution Approach 2:
The system dynamically selects which line heads and nozzle holes are active based on the desired pattern. The control unit can flexibly activate different combinations of line heads and nozzle holes to match various pattern requirements, providing adaptability without physical replacement of components
2Productivity
If multiple line heads with multiple nozzle holes are used to increase resolution and adjustment range, then production efficiency improves, but the device complexity increases
Solution Approach 1:
Each line head is designed with multiple nozzle holes that can serve different functions depending on the pattern requirement. The same line head structure can be used for various patterns by selectively activating different nozzle holes, reducing the need for multiple specialized components and managing complexity through multi-functionality
Solution Approach 2:
The line heads and nozzle holes are pre-configured in specific arrangements before production. The control unit stores pattern information and pre-determines which nozzle holes to activate, allowing complex patterns to be formed without real-time complex decision-making, thus managing operational complexity
3Productivity
If the support is conveyed through the line head group only once, then production efficiency improves, but achieving uniform thin film formation with high resolution becomes more difficult
Solution Approach 1:
Different line heads and nozzle holes are assigned to different regions of the support width direction. Each nozzle hole targets a specific local region, allowing precise control of coating liquid deposition in different areas. This local quality control ensures uniform thin film formation across the entire support even during single-pass conveyance
Solution Approach 2:
The system uses delay time control for each line head relative to the support conveyance speed to achieve precise positioning. The control unit calculates and adjusts the discharge timing of each nozzle hole based on the conveyance speed and position, providing feedback control that ensures accurate coating liquid placement and uniform film formation
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 enhances the resolution and adjustment range for thin film formation, improving production efficiency and achieving uniformity in thin film thickness and pattern formation.
Implementation Method 1
a coating liquid containing a thin film forming material is discharged onto a support in an ink jet manner
Implementation Method 2
discharged from nozzle holes 28 arranged in the width direction D2
Implementation Method 3
the coating film 16 is dried to produce a thin film 10
Data Source
AI summary
A thin film production method according to one embodiment includes: a coating film forming step of forming a coating film by discharging a coating liquid on a support from first to M-th line heads (M is 2 or larger and N or smaller) while allowing the support to pass through N line heads once; and a drying step of obtaining a thin film by drying the coating film. A thin film forming nozzle hole 28 of the m-th line head (m is 2 or larger and M or smaller) is arranged to be positioned between adjacent thin film forming nozzle holes in an (m−1)-th thin film forming nozzle hole array Qm-1. Every time the first line head discharges the coating liquid, the m-th line head applies the coating liquid onto the support at a predetermined delay time with respect to a discharge time of the first line head. The first to M-th line heads discharge the coating liquid from the film forming nozzle hole selected in accordance with a shape of a thin film formation region onto the support.