Integrated Coating System for Multi-Viscosity Web Processing
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Solution Overview
Problem
Current printing technologies for electronic devices are complex and costly due to the need for multiple specialized machines for handling materials with varying viscosities, leading to increased equipment costs and process complexity, especially when dealing with high-priced materials and complex integrated circuit configurations.
Innovation Solution
An integrated coating system with modulated printing and curing means that can selectively use different techniques based on material viscosity, allowing for the use of materials from low to ultra-high viscosity without the need for multiple machines, by positioning printing and curing units appropriately along the web path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple specialized printing machines are used for materials with different viscosities, then the ability to handle various materials is improved, but the device complexity and equipment cost increase
Solution Approach 1:
The patent implements a single printing machine capable of performing multiple printing functions by integrating different printing units (gravure, flexo, offset, screen printing) within one device. This universal machine can handle materials with various viscosities by selecting the appropriate printing unit, eliminating the need for multiple specialized machines and thereby reducing device complexity while maintaining versatility
Solution Approach 2:
The printing machine is divided into multiple independent printing units, each specialized for specific viscosity ranges or material types. These segmented units can be selectively activated based on the material being processed, allowing the system to maintain adaptability while managing complexity through modular architecture
2Adaptability or versatility
If multiple specialized printing machines are used for materials with different viscosities, then the ability to handle various materials is improved, but the equipment cost increases
Solution Approach 1:
By creating a universal printing machine that integrates multiple printing technologies (gravure, flexo, offset, screen printing) into one device, the patent eliminates the need to purchase and maintain multiple separate specialized machines. This significantly reduces equipment investment costs while maintaining the ability to handle materials with various viscosities
Solution Approach 2:
The patent merges multiple printing units and their associated systems (ink supply, drying, substrate handling) into a single integrated machine. This consolidation reduces overall equipment cost by sharing common infrastructure and eliminating redundant systems that would exist if separate machines were used
3Adaptability or versatility
If substrates are moved between multiple machines for printing, then the ability to process various materials is improved, but the productivity decreases
Solution Approach 1:
The integrated printing machine allows substrates to be processed continuously without being moved between different machines. The substrate passes through multiple printing units and drying sections in sequence within one machine, maintaining productivity while handling various materials with different viscosities
Solution Approach 2:
The printing machine is designed to perform multiple printing operations and drying processes in continuous sequence without interrupting substrate movement. This continuous action maintains high productivity by eliminating the downtime and handling operations associated with moving substrates between separate machines
4Adaptability or versatility
If multiple specialized printing machines are used, then the ability to handle various materials is improved, but the process complexity increases
Solution Approach 1:
The integrated printing machine provides a unified control system that manages multiple printing units and drying sections. This centralized control simplifies the operating process by allowing operators to select the appropriate printing mode for different materials without coordinating multiple separate machines, thereby reducing process complexity while maintaining the ability to handle various materials
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 system simplifies the process design, reduces equipment costs, and improves production efficiency by enabling the use of various materials with a single set of integrated equipment, eliminating the need to move substrates between different machines and allowing for more flexible and accurate processing of complex multilayer configurations.
Implementation Method 1
a plurality of curing means each of which is modulated so that at least one of the curing means is selectively used to cure a printing material on the web passing through at least one printing means
Implementation Method 2
enabling various curing methods such as IR/UV irradiation, direct heating, and hot wind drying
Implementation Method 3
enabling various curing methods such as IR/UV irradiation, direct heating, and hot wind drying
Data Source
AI summary
Provided is an integrated coating system. An integrated coating system according to an exemplary embodiment of the present invention includes: a unwinding means provided with a roll to supply a web; a worktable roll configured to support the web supplied from the unwinding means; a plurality of printing means configured to perform printing or coating on the web supplied from the unwinding means; a plurality of curing means each of which is modulated to cure a printing material on the web passing through at least one printing means; and a winding means around which the web, of which printing or coating work is completed by passing through the curing means, is wound in a roll shape.