Computer-Controlled Metering Head for Precise Coating Patterning
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Solution Overview
Problem
Existing surface coating methods lack accurate metering and selective coating capabilities, making them unsuitable for precise applications, and are often complex and costly, especially for small-scale or selective surface patterning.
Innovation Solution
A method using a computer-controlled metering head with nozzles that can be actuated by control signals to apply fluid coating materials accurately, allowing for precise metering and patterning of surfaces, including the use of heated materials to reduce viscosity and a superatmospheric pressure system for processing high and medium viscosity materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If contactless coating methods (spraying, flooding, extrusion, pouring, dipping, slot dies, cap coating) are used, then coating application is achieved, but accurate metering of coating material is not possible
Solution Approach 1:
The patent replaces conventional mechanical coating systems (spraying, flooding, extrusion, pouring, dipping, slot dies, cap coating) with a computer-controlled metering head that uses precise mechanical dosing mechanisms. This substitution enables accurate metering of coating material while maintaining contactless application capability, directly resolving the contradiction between measurement precision and ease of manufacture.
Solution Approach 2:
The metering head is designed to automatically control and meter the coating material application based on computer-generated control signals. The system performs self-regulation of coating quantity and placement without requiring manual intervention, achieving both accurate metering and ease of operation simultaneously.
2Adaptability or versatility
If contactless coating methods are used, then coating application is achieved, but selective coating of selected regions is not possible
Solution Approach 1:
The coating application system is segmented into multiple independently controllable nozzles arranged in arrays. Each nozzle can be individually actuated by computer control to apply coating to specific regions of the substrate. This segmentation enables selective coating of different areas while maintaining the simplicity of the overall coating process.
Solution Approach 2:
The system dynamically controls the actuation of individual nozzles based on the required coating pattern and substrate position. The computer-controlled metering head can adaptively activate specific nozzle groups to create various coating patterns, achieving selective coating capability without complicating the basic coating application process.
3Adaptability or versatility
If subsequent patterning methods (photoresist patterning, mask exposure) are used, then selective coating is achieved, but additional working operations are required
Solution Approach 1:
The patent performs the patterning action during the coating application process itself, rather than requiring subsequent separate patterning steps. The computer-controlled metering head applies coating material directly to predetermined patterns on the substrate in one operation, eliminating the need for separate photoresist application, exposure, and developing steps.
Solution Approach 2:
The patent combines the coating application function with the patterning function into a single integrated process. The metering head simultaneously performs both tasks by controlling material deposition to specific regions, merging what were previously separate sequential operations into one unified process, thereby reducing total processing time.
4Manufacturing precision
If conventional coating methods are used, then coating application is achieved, but high accuracy patterning is not possible
Solution Approach 1:
The patent replaces conventional mechanical coating systems with a computer-controlled metering head that uses precise electronic control mechanisms. This substitution enables high-accuracy patterning through digital control of material deposition, achieving manufacturing precision without requiring complex mechanical patterning mechanisms.
Solution Approach 2:
The system uses computer-generated control signals to precisely replicate the desired coating pattern. The digital control system copies the target pattern into the physical coating application process, enabling high accuracy patterning through software control rather than complex mechanical systems.
5Adaptability or versatility
If coating methods are used for small-scale applications, then selective coating is possible, but costs and work involved are high
Solution Approach 1:
The patent segments the coating application into precise, controlled deposits at specific locations. This segmentation enables selective coating of only the required areas, reducing material consumption and processing costs for small-scale applications while maintaining the capability to handle various substrate sizes and configurations.
Solution Approach 2:
The system adjusts coating parameters (material quantity, deposition speed, temperature, pressure) to optimize performance for different application scales. The computer-controlled metering head can adapt parameters to match the specific requirements of small-scale versus large-scale production, making the system cost-effective across different production volumes.
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
Enables highly accurate and efficient application of coatings with precise metering and patterning capabilities, suitable for various surfaces and materials, including those with high viscosity, and allows for the production of complex patterns and multi-layer structures with high throughput.
Implementation Method 1
the fluid coating material can be preheated in order to reduce the viscosity. Accordingly, according to one embodiment of the invention the apparatus according to the invention has a preheating device for heating the fluid material. For example, the viscosity can be reduced by heating the fluid coating material to up to 300° C., preferably to up to 125° C., particularly preferably to up to 80° C.
Implementation Method 2
The fluid coating material may be applied with particular success by spraying on droplets through a nozzle if the application is carried out using a viscosity of the coating material of from 8 to 100 mPa·s, preferably 8 to 50 mPa·s, particularly preferably 8 to 25 mPa·s.
Implementation Method 3
The fluid coating material may also be fed to the nozzle under superatmospheric pressure. For this purpose, the apparatus according to the invention may, for example, have at least one pump device connected upstream of the nozzle as superatmospheric pressure system.
Data Source
AI summary
A method and apparatus for applying coatings, such as in particular varnishes, to surfaces is provided. The apparatus includes a metering head that has at least one nozzle which can be actuated by a control signal. The method includes the steps of: moving a base having a surface that is to be coated along this surface relative to a metering head and/or moving the metering head relative to a surface of the base, and applying a fluid coating material to the surface through a nozzle in response to at least one control signal generated by a computer.