Sheet Coating Method Using Plug Flow Fluid Through Gaps
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Solution Overview
Problem
Current methods for coating thin glass films, such as vacuum-based vapor deposition and layer-by-layer self-assembly, are expensive and not economically feasible for high-throughput production, particularly when applying multiple layers in a continuous roll-to-roll fashion, requiring large footprints and high costs.
Innovation Solution
A method involving a reactor with a plurality of sheets spaced with gaps, where a fluid with a plug flow profile is forced through the gaps to deposit coatings on the sheets in a self-limiting process, optimizing reactant usage and reducing cycle time, allowing for high-performance coatings at low costs and high throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vacuum-based vapor deposition or traditional LBL coating is used, then coating quality is maintained, but production cost increases and throughput decreases
Solution Approach 1:
The system segments the coating process by placing multiple sheets in a stack with gaps between them, allowing fluid to flow through individual gaps to coat each sheet separately. This enables parallel processing of multiple sheets simultaneously, dramatically increasing throughput while using simple, cost-effective equipment compared to vacuum-based systems.
Solution Approach 2:
The invention uses fluid flow (hydraulic/pneumatic principle) to deliver coating precursors through the gaps between sheets. The fluid is forced through the gaps at controlled flow rates to achieve uniform coating deposition, replacing expensive vacuum-based vapor deposition with a simpler, ambient-pressure liquid or gas flow system.
2Manufacturing precision
If multiple layers are coated using traditional LBL spray or dip coating, then coating performance is achieved, but equipment footprint becomes large
Solution Approach 1:
The invention transitions from traditional horizontal spray or dip coating to a vertical stack configuration where sheets are arranged in the vertical dimension with gaps between them. Fluid flows horizontally through these vertical gaps, enabling multiple layers to be coated in a compact vertical footprint rather than requiring extensive horizontal coating line space.
Solution Approach 2:
Multiple sheets are nested in a vertical stack configuration, with each sheet positioned within the overall stack structure. The fluid flows through the nested gaps between sheets, allowing multiple coating surfaces to be accessed simultaneously within a compact nested arrangement, minimizing the overall equipment footprint.
3Reliability
If batch coating processes are used, then coating quality is maintained, but production time increases
Solution Approach 1:
The system enables continuous coating operation by maintaining constant fluid flow through the sheet stack gaps. Multiple sheets can be coated simultaneously and continuously processed through the reactor, eliminating the batch-to-batch interruptions inherent in traditional dip or spray coating, thereby reducing total production time while maintaining coating quality.
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 enables efficient, high-throughput coating of thin glass sheets with high-performance coatings, such as antireflectors and conductive layers, at reduced costs by minimizing reactant consumption and cycle time, while maintaining coating uniformity and flexibility in design.
Implementation Method 1
The fluid has a substantially plug flow profile and the fluid deposits a coating on at least one surface of the plurality of sheets in a self-limiting deposition process
Data Source
AI summary
A method of coating a plurality of sheets. A fluid is forced through gaps in the plurality of sheets. The fluid has a substantially plug flow profile and the fluid deposits a coating on at least one surface of the plurality of sheets in a self-limiting deposition process.