Multi-Outlet Viscous Material Deposition Nozzle for Film Thickness Control
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Solution Overview
Problem
Current nozzles for applying viscous materials are limited in application width and lack thickness control, requiring additional tools and causing material waste.
Innovation Solution
A viscous material deposition nozzle with a pair of lifts and a stepped application surface, featuring a V-shaped distribution cavity and multiple outlets, allows for wider film deposition and precise thickness control through a trailing face that scrapes the material to a finished thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single elongated outlet nozzle is used, then the nozzle structure is simple, but the application width is limited
Solution Approach 1:
The single elongated outlet is segmented into multiple outlets (first outlet, second outlet, and additional outlets) arranged in a array. This segmentation allows the nozzle to cover a wider application width by distributing material through multiple smaller outlets rather than one large outlet, resolving the contradiction between simple structure and wide application coverage.
Solution Approach 2:
The nozzle transitions from a single linear outlet to a two-dimensional array of multiple outlets. This dimensional change enables wider material distribution across the substrate surface while maintaining a compact nozzle structure, effectively increasing application width without proportionally increasing overall nozzle size.
2Loss of substance
If material is extruded without thickness control, then the application process is simple, but material waste increases
Solution Approach 1:
The nozzle incorporates a self-contained thickness control mechanism where the bottom surface of the application surface acts as a scraper that automatically controls material thickness as it contacts the substrate. This self-service feature eliminates the need for external scraping tools or complex adjustment mechanisms, reducing material waste while maintaining operational simplicity.
Solution Approach 2:
The thickness control function is merged with the nozzle structure itself. The bottom surface of the application surface serves dual purposes: it defines the outlet geometry for material extrusion and simultaneously acts as a scraping surface to control material thickness. This integration eliminates the need for separate thickness control devices, reducing overall system complexity.
3Manufacturing precision
If additional tools are used for thickness control, then thickness precision is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The thickness control function is merged with the nozzle structure itself. The bottom surface of the application surface serves dual purposes: it defines the outlet geometry for material extrusion and simultaneously acts as a scraping surface to control material thickness. This integration eliminates the need for separate thickness control devices, reducing overall system complexity.
Solution Approach 2:
The nozzle is pre-configured with a bottom surface geometry designed to scrape and control material thickness during the extrusion process itself. This preliminary design of the nozzle structure ensures that thickness control is built into the application process, eliminating the need for subsequent scraping operations or additional thickness adjustment steps.
4Stability of the object's composition
If a single outlet nozzle is used, then the nozzle design is simple, but the distribution uniformity is poor
Solution Approach 1:
The single outlet is segmented into multiple outlets (first outlet, second outlet, and additional outlets) arranged in a array. This segmentation allows the nozzle to cover a wider application width by distributing material through multiple smaller outlets rather than one large outlet, resolving the contradiction between simple structure and wide application coverage.
Solution Approach 2:
Each outlet in the array is positioned and sized to deliver material to specific local areas of the substrate. The bottom surfaces of the outlets can have different geometries optimized for their specific positions, ensuring uniform material distribution across the entire application width while maintaining overall nozzle structural simplicity.
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 wider film deposition of viscous materials with controlled thickness, reducing manufacturing time, cost, and waste while allowing for self-supporting additive manufacturing.
Implementation Method 1
V-shaped distribution cavity configured to distribute a viscous material from an inlet
Implementation Method 2
distribute a viscous material from an inlet to a plurality of outlets
Implementation Method 3
trailing face a second distance from the contact surfaces... scrape the viscous material
Data Source
AI summary
A viscous material deposition nozzle and methods of use are provided. The viscous material deposition nozzle comprises a pair of lifts, an application surface, and a plurality of outlets. The pair of lifts is positioned on a first side and a second side of the viscous material deposition nozzle and comprises contact surfaces. The application surface is positioned between the pair of lifts and comprises a leading face a first distance from the contact surfaces and a trailing face a second distance from the contact surfaces. The second distance is less than the first distance. The plurality of outlets extend through the application surface.