Light Emitting Device Slurry Coating with Bubble Stirring
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Solution Overview
Problem
The existing methods for manufacturing light emitting devices with optical matter particles often suffer from decreased coating quality due to sedimentation and inadequate dispersion of these particles in the slurry, leading to suboptimal performance.
Innovation Solution
A method involving a bubble producing unit below the slurry surface to stir and prevent sedimentation, combined with a spray coating process that circulates the slurry between tanks to ensure uniform dispersion of optical matter particles before application onto a light emitting element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the slurry is stored statically in a slurry tank, then the manufacturing process is simple, but the optical matter particles sediment and coating quality deteriorates
Solution Approach 1:
The patent applies preliminary action by circulating the slurry before spray coating to prevent sedimentation of optical matter particles. The slurry circulation unit continuously stirs the slurry in the slurry tank, ensuring uniform dispersion of particles before they are supplied to the spray nozzle, thereby maintaining high coating quality without requiring complex additional equipment.
Solution Approach 2:
The patent implements continuity of useful action by maintaining continuous slurry circulation between the slurry tank and the spray nozzle. This continuous movement prevents particle settlement and ensures consistent optical matter particle distribution throughout the coating process, resolving the contradiction between simple storage and high coating quality.
2Manufacturing precision
If the slurry is circulated between two slurry tanks, then particle dispersion is improved, but the device complexity and process time increase
Solution Approach 1:
The patent uses preliminary action by pre-circulating the slurry in a single slurry tank with an integrated circulation unit before coating. This preliminary stirring ensures particles are uniformly dispersed and prevents sedimentation during the coating process, achieving the same particle uniformity as two-tank circulation but without the additional time and complexity of transferring slurry between tanks.
3Ease of manufacture
If optical matter particles are not dispersed in the slurry, then the manufacturing process is simpler, but coating quality decreases due to sedimentation
Solution Approach 1:
The patent applies self-service by incorporating a circulation unit within the slurry tank that automatically stirs and circulates the slurry without external intervention. This self-circulating system maintains particle dispersion and prevents sedimentation, ensuring high coating quality while keeping the manufacturing process simple and integrated.
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 significantly improves the coating quality of optical matter particles, enhancing the performance and efficiency of the light emitting device by maintaining particle uniformity and preventing sedimentation during the manufacturing process.
Implementation Method 1
stirring the slurry by causing a bubble producing unit arranged below a liquid surface of the slurry to produce bubbles inside the slurry tank
Data Source
AI summary
The method includes the steps of: storing slurry containing optical matter particles into a slurry tank; stirring the slurry inside the slurry tank by causing a bubble producing unit arranged below a liquid surface of the slurry to produce bubbles; and spraying the slurry onto a coating target including a light emitting element from a nozzle arranged above the coating target.