Staggered Inkjet Nozzle Head for High-Definition Coating
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Solution Overview
Problem
The existing inkjet methods face challenges in achieving high-definition coating due to limitations in nozzle pitch, difficulty in detecting ejection abnormalities, forming uniform film thickness, and managing complex piping and wiring systems, which affect the precision and efficiency of the coating process.
Innovation Solution
The solution involves an inkjet head with line-type nozzles arranged in a staggered manner to reduce nozzle pitch, an abnormality detection method using image analysis to calculate liquid width, a film forming method with gray level distribution charts for uniform thickness, and a simplified piping system with a common liquid feed pipe and separate gas flow pipes to improve movement and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional inkjet nozzles are used with limited nozzle pitch adjustment capability, then the device structure is simple, but high-definition coating cannot be achieved
Solution Approach 1:
The inkjet head is divided into multiple nozzle units, each containing multiple nozzles arranged in series. These nozzle units are further arranged in parallel with staggered positioning, allowing independent control and precise adjustment of dot pitch to achieve high-definition coating
Solution Approach 2:
The patent introduces a staggered arrangement in the vertical dimension (direction perpendicular to the nozzle row) in addition to the horizontal arrangement. This multi-dimensional positioning enables finer control over droplet placement and achieves narrower effective nozzle pitch
2Reliability
If ejection abnormality detection is not implemented, then the device is simpler, but coating quality cannot be ensured
Solution Approach 1:
An ejection abnormality detection system is integrated into the inkjet head, using imaging devices to capture droplet ejection states and process this information to identify abnormalities. This feedback mechanism enables real-time monitoring and quality control
Solution Approach 2:
The detection system replaces complex mechanical inspection methods with optical imaging and digital processing. By capturing images of ejected droplets and analyzing them through image processing, the system identifies ejection abnormalities without requiring complex mechanical measurement devices
3Reliability
If multiple separate piping systems are used for liquid feed and gas flow, then each function can be optimized independently, but the overall system becomes complex
Solution Approach 1:
The patent combines the liquid feed pipe and gas flow pipe into a single integrated piping structure. The gas flow pipe is positioned inside the liquid feed pipe, allowing both functions to coexist in one assembly, reducing overall system complexity while maintaining independent functional control
Solution Approach 2:
The gas flow pipe is nested within the liquid feed pipe, creating a concentric structure where the gas flow channel is positioned inside the liquid supply channel. This nested arrangement reduces the space required and simplifies the overall piping configuration
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 allows for narrower nozzle pitches, precise adjustment of dot pitches, reliable ejection abnormality detection, uniform film thickness, and reduced complexity in piping and wiring, enhancing the overall precision and efficiency of the coating process.
Implementation Method 1
a so-called inkjet method using an inkjet head has been widely employed in a case of performing printing using ink on a print medium
Implementation Method 2
a light source and image taking means are arranged so as to face a scattering plate, and a liquid droplet which is an object to be measured is positioned among the light source, the image taking means, and the scattering plate, and light irradiated from the light source is scattered by the scattering plate
Data Source
AI summary
There are provided n number of line-type inkjet nozzles (2) which include nozzles (4) that eject a liquid material and are arranged in a row, and which are arranged in parallel with each other so that positions of the nozzles (4) are shifted from each other by 1/n of a nozzle pitch (P1). Thus, an inkjet head (1) as a whole has a state equivalent to a state in which the nozzles (4) are arranged at 1/n of a nozzle pitch of one line-type inkjet nozzle (2). The inkjet head (1) is capable of adjusting a timing of ejecting the liquid material for each line-type inkjet nozzle (2). Accordingly, adjustment of a dot pitch such as fine coating and rough coating can be performed with ease.