Replaceable Shim Coating Module for Uniform Liquid Distribution
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Solution Overview
Problem
Current coating devices face high manufacturing and production costs due to the need for complex diversion structures and frequent replacement of shims to maintain uniformity, making them difficult to share across different film-coating processes and increasing product costs.
Innovation Solution
A coating module with two plates and a diversion structure featuring a slot with a slot inlet and outlet, where the diversion structure is integrated into the fixtures, allowing for easy replacement of worn plates and adaptation to different diversion patterns, reducing production costs and improving reusability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex diversion structures (T-die type, fishtail type, or coat-hanger type) are used to achieve uniform liquid distribution, then coating uniformity is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The coating device is divided into a reusable fixture and replaceable shim modules. The shim contains the diversion structure and can be independently replaced without replacing the entire fixture, thereby reducing device complexity while maintaining coating uniformity through standardized designs.
Solution Approach 2:
The fixture is designed as a universal component that can accommodate multiple different shim types (T-die type, fishtail type, coat-hanger type) with different diversion structures. This allows the same fixture to serve multiple coating applications while maintaining uniform liquid distribution through appropriate shim selection.
2Manufacturing precision
If shims with complex diversion structures are used to reduce residue zones and recirculation zones, then coating uniformity is improved, but manufacturing cost increases
Solution Approach 1:
The shim is designed as a separate, replaceable component that can be manufactured independently using optimized processes for each diversion structure type. This segmentation allows specialized manufacturing techniques to be applied to each shim type, reducing overall manufacturing costs while maintaining high coating uniformity.
Solution Approach 2:
Different shim designs with varying diversion structure parameters (T-die, fishtail, coat-hanger) are optimized for specific coating liquid characteristics and coating methods. By matching shim parameters to application requirements, coating uniformity is maximized without unnecessarily increasing manufacturing cost for all applications.
3Manufacturing precision
If the entire coating device is replaced when the restrictor gets worn, then coating uniformity is maintained, but production cost increases
Solution Approach 1:
The shim containing the restrictor is designed as a replaceable component separate from the main fixture. When the restrictor becomes worn, only the shim needs to be replaced rather than the entire coating device, significantly reducing production costs while maintaining coating uniformity through replacement with a new or reconditioned shim.
Solution Approach 2:
The reusable fixture is designed to be durable and long-lasting, while the shim is designed for periodic replacement. This allows the expensive fixture to be recovered and reused multiple times, while only the less expensive shim is discarded or reconditioned, optimizing the balance between maintaining coating uniformity and controlling production costs.
Data Source
AI summary
A coating module is suitable to coat a liquid onto a substrate and includes two plates and a diversion structure, in which there is a slot between the plates, and the slot has a slot inlet and a slot outlet, and one of the plates has an injecting port. The diversion structure makes the injecting port communicated with the slot inlet, in which the liquid is configured to enter the diversion structure via the injecting port, and flow to the slot inlet through the diversion structure, then flow into the slot via the slot inlet and then outflows from the slot via the slot outlet to be coated onto the substrate.