Film Forming Apparatus Mist Spray Nozzle Clogging Prevention

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Solution Overview

Problem

The mist spray nozzle in existing film forming apparatuses is prone to clogging due to reactions between atomized raw materials and residual moisture, leading to particle generation and attachment at the spray orifice.

Innovation Solution

A film forming apparatus with a mist spray head featuring a raw material spray nozzle having a first cavity with a raw material supply part and a discharge part drilled on its side surface, away from the bottom, which traps particles generated by reactions within the nozzle, preventing clogging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a mist spray nozzle is used to spray atomized raw material in an atmospheric pressure film forming apparatus, then film formation can be performed without a large vacuum case, but particles are generated by reaction between the atomized raw material and residual moisture in the nozzle, causing clogging of the spray orifice

Engineering Contradiction:
Improvevacuum caseVSAvoidspray orifice clogging
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The spray nozzle is divided into multiple functional parts: a spray hole formation part with spray orifices for material ejection, and a separate raw material introduction part with introduction holes that do not directly contact the spray orifices. This segmentation prevents particles generated in the raw material introduction path from reaching and clogging the spray orifices.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The harmful function of particle generation is extracted and isolated to a specific region (the raw material introduction part) that is separated from the spray hole formation part. Particles are generated and trapped in the introduction holes rather than being carried to the spray orifices, effectively removing the clogging problem from the spray function.

Inventive Principle:
Principle #2Taking out (Extraction)

2Productivity

If the raw material discharge part is positioned close to the bottom surface of the cavity to maximize spray efficiency, then atomized material can be ejected more effectively, but particles generated by reaction will attach to the discharge part and cause clogging

Engineering Contradiction:
Improvespray efficiencyVSAvoidparticle attachment
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The nozzle structure separates the raw material introduction function from the spray ejection function. The raw material discharge part introduces material through holes in the cavity wall away from the bottom, while spray orifices are formed separately in the bottom surface. This segmentation allows the discharge part to be positioned optimally for material introduction without being susceptible to particle attachment that would occur if it were at the bottom.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The cavity structure acts as an intermediary chamber that receives raw material through introduction holes from the raw material discharge part, then delivers it to the spray orifices in the bottom surface. This intermediary space allows particle-laden raw material to be processed and delivered without the discharge part itself being exposed to conditions that cause particle attachment and clogging.

Inventive Principle:
Principle #24Intermediary (Mediator)

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

Prevents particle attachment and clogging in the ejection part by trapping particles between the nozzle's bottom surface and discharge part, ensuring continuous and efficient film formation on substrates.

Implementation Method 1

an atomized raw material is sprayed to the substrate

Methodology Applied
Scientific EffectAtomization:

Implementation Method 2

the raw material and a residual moisture react with each other in the cavity in the raw material spray nozzle and particles are thereby generated

Methodology Applied
Scientific EffectChemical reaction:

Implementation Method 3

a raw material discharge part which is drilled in a side surface of the first cavity, being away from a bottom surface of the first cavity, and is connected to the raw material ejection part

Methodology Applied
Scientific EffectFluid flow through drilled passage:

Implementation Method 4

sprays an atomized raw material to an atmosphere so as to form a film on a substrate

Methodology Applied
Scientific EffectFilm deposition: Deposition (physical)

Data Source

PatentUS10118191B2Film forming apparatus
Publication Date: 2018.11.06 TMEIC CORP
  • US10118191B2 patent drawing
  • US10118191B2 patent drawing
  • US10118191B2 patent drawing

AI summary

A film forming apparatus includes a mist spray head for spraying a raw material. The mist spray head includes a raw material spray nozzle and a raw material ejection part for ejecting an atomized raw material, and the raw material spray nozzle includes a cavity and a raw material discharge part which is drilled in a side surface of the cavity, being away from a bottom surface of the cavity, and is connected to the raw material ejection part.