Pivotable Blade Coating System for Laser Transparent Substrates
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Solution Overview
Problem
Existing methods for coating substrates with highly viscous materials lack precision in achieving uniform and controlled layer thickness, particularly for laser radiation transparent substrates.
Innovation Solution
A system and method utilizing a pivotably mounted layer thickness uniformizing blade with a straight edge, applied on a linearly displaceable blade support, which allows for precise control of the donor material thickness by adjusting the separation distance between the blade and the substrate, enabling sequential reduction of the material thickness to a desired range of 10 to 2000 microns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional coating method is used for highly viscous materials, then the coating process is simple, but the layer thickness uniformity and precision are poor
Solution Approach 1:
The patent changes the physical parameters of the coating system by introducing a pivotable blade mechanism that can be precisely positioned at different heights above the substrate. By adjusting the blade's vertical position (a key parameter), the system achieves precise control over the coating thickness of highly viscous materials, transforming a simple but imprecise process into a controlled, parameter-driven process that delivers uniform layers.
Solution Approach 2:
The blade is designed to be pivotable rather than fixed, allowing it to dynamically adjust its position and orientation during the coating process. This dynamic capability enables the blade to maintain optimal separation from the substrate while accommodating variations in material viscosity and flow characteristics, thereby achieving uniform coating thickness without requiring an overly complex multi-component system.
2Manufacturing precision
If the blade is positioned close to the substrate for thin coating, then the coating thickness is reduced, but the blade may contact the substrate causing non-uniformity
Solution Approach 1:
The pivotable blade mechanism allows the coating system to dynamically adjust the blade's position and angle during operation. When coating thin layers, the blade can be positioned close to the substrate while the pivot mechanism ensures it maintains an optimal separation distance, preventing direct contact that would cause non-uniformity. This dynamic adjustment capability enables precise thickness control without sacrificing coating reliability.
Solution Approach 2:
The system preemptively prevents blade-substrate contact by maintaining a controlled separation distance through the pivotable mounting mechanism. By designing the blade to pivot rather than remain fixed, the system anticipates and prevents the harmful effect of blade contact before it occurs, ensuring uniform coating even when operating at minimal separation distances for thin layer deposition.
3Manufacturing precision
If the blade is fixed in position, then the device complexity is reduced, but the ability to achieve uniform thickness on large substrates is limited
Solution Approach 1:
The pivotable blade mounting mechanism provides a dynamic solution that enables uniform coating across large substrate areas. The blade can pivot to accommodate variations in substrate geometry and maintain consistent separation distance across the entire coating area, achieving thickness uniformity that would be impossible with a fixed blade position, while avoiding the complexity of multiple independent positioning systems.
Solution Approach 2:
The pivotable blade mechanism serves multiple functions: it maintains optimal separation distance, accommodates substrate size variations, and ensures uniform coating thickness across the entire surface. This single multi-functional mechanism replaces what would otherwise require multiple separate positioning and adjustment systems, achieving high precision coating without proportionally increasing device complexity.
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 ensures precise and uniform coating of highly viscous materials on laser radiation transparent substrates, achieving the desired thickness with high accuracy and consistency.
Implementation Method 1
the locking the layer thickness uniformizing blade against pivotable movement relative to the linearly displaceable blade support about the pivot axis is provided by operation of an electromagnet mounted onto the linearly displaceable blade support by attracting a locking arm, fixed to the layer thickness uniformizing blade
Data Source
AI summary
A system for coating of a donor material onto a laser radiation transparent substrate, the system including a donor material applicator, applying donor material to the laser radiation transparent substrate, a multi-pass precise donor material thickness determiner for providing a desired thickness of the donor material on the laser radiation transparent substrate and including a linearly displaceable blade support, a layer thickness uniformizing blade lockably pivotably mounted onto the linearly displaceable blade support about a pivot axis, the blade having a straight edge and a blade position maintainer operative for maintaining the straight edge at a desired separation distance from the laser radiation transparent substrate, the separation distance being uniform along the straight edge of the layer thickness uniformizing blade.