Liquid Flow Converging Device for High-Layer Film Manufacturing
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Solution Overview
Problem
Conventional liquid stream combining apparatuses are limited in producing multilayered films with 700 or more layers at high accuracy and are prone to generating foreign matters and layer deformation, especially when producing films with complex layer thickness constellations like refractive index control films.
Innovation Solution
A liquid stream combining apparatus comprising multiple components with slits and stream combining sections that allow for the precise layering of liquid streams, enabling the formation of multilayered films with 700 or more layers and allowing for the control of layer thicknesses, using thermoplastic resins like polyethylene terephthalate, and incorporating features such as slit design and liquid retaining sections to maintain high accuracy and prevent foreign matter generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the apparatus is enlarged to produce multilayered films with more layers, then the number of layers can be increased, but stagnant liquid regions are formed causing thermal deterioration and foreign matter generation
Solution Approach 1:
The apparatus is divided into multiple independent component sets, each capable of forming layered liquid streams. This segmentation allows the system to achieve high layer counts without requiring a single large apparatus, thereby avoiding stagnant liquid regions and thermal deterioration that would generate foreign matters.
Solution Approach 2:
Multiple component sets are arranged in a nested configuration where the output of one component feeds into the input of another. This nesting allows efficient space utilization and maintains continuous liquid flow throughout the apparatus, preventing stagnation and foreign matter generation while achieving high layer counts.
2Quantity of substance
If conventional apparatuses are used to produce multilayered films with 700 or more layers, then the number of layers can be increased, but layer deformation occurs due to passage deformation in the mixer
Solution Approach 1:
The liquid stream combining function is segmented across multiple independent components rather than using a single mixer. This segmentation eliminates passage deformation issues in conventional mixers, maintaining layer accuracy even when producing films with 700 or more layers.
Solution Approach 2:
The apparatus transitions from a single-plane mixing approach to a multi-dimensional arrangement where multiple component sets process liquid streams in parallel and perpendicular directions. This dimensional change allows efficient layer formation without the passage deformation that causes layer accuracy loss in conventional single-plane mixers.
3Adaptability or versatility
If the apparatus is enlarged to produce multilayered films with complex layer thickness constellations, then the layer constitution can be made more complex, but the apparatus size increases causing the same stagnant liquid region problems
Solution Approach 1:
The apparatus uses multiple independent component sets that can be configured to produce various layer thickness constellations. This segmentation allows complex layer patterns to be achieved within a compact footprint, avoiding the need to enlarge the apparatus while maintaining versatility.
Solution Approach 2:
The component configuration is designed to be dynamically adjustable, allowing the same apparatus to produce different layer thickness constellations by reconfiguring the number and arrangement of active components. This dynamic capability provides versatility without requiring apparatus enlargement.
Data Source
AI summary
A liquid flow converging device and a method of manufacturing a multi-layer film. The converging device comprises an element (A) having a large number of slits for passing two liquid flows to be converged therethrough and an element (B) having a first converging part for converging, in a laminar form, a large number of laminar liquid flows formed by passing the liquid flows through the large number of slits to form a first laminar liquid flow. The converging device for the liquid flow comprises a first confluence forming device having two or more elements (A) installed independently of each other and two or more elements (B) installed independently of each other.