Wicking-Head PSA Printing for High-Throughput Adhesive Deposition
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Solution Overview
Problem
Current screen printing techniques for pressure sensitive adhesives (PSA) pose environmental health and safety concerns due to solvent use, solvent evaporation affecting printing quality, and require frequent cleaning, leading to material scrapping and production disruptions.
Innovation Solution
A dispensing system with a rigid support structure, dispensing heads, and a closed feeding system, coupled with a robotic handling system, that uses a wicking structure to hold PSA solution in place and deposit it in a desired shape without continuous supply, minimizing solvent evaporation and enabling high throughput production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If screen printing techniques are used to print PSA, then the adhesive can be applied to substrates, but solvent evaporation causes the solvent to become thicker and affects printing quality
Solution Approach 1:
The patent changes the physical state of the PSA from a solvent-based liquid to a melt-extrudable thermoplastic adhesive. This parameter change eliminates solvent evaporation entirely, as the adhesive is applied in a molten state and solidifies upon cooling, maintaining consistent viscosity and printing quality throughout the process.
Solution Approach 2:
The patent replaces the screen printing mechanical system with a hot melt dispensing system that uses controlled melting and extrusion. This substitution eliminates the need for mesh screens and solvent-based application, directly addressing the printing quality issues caused by solvent evaporation.
2Productivity
If screen printing techniques are used to print PSA, then the adhesive can be applied to substrates, but the screen requires frequent cleaning which leads to material scrapping and production disruptions
Solution Approach 1:
The patent extracts and eliminates the screen component from the adhesive application system. By using direct hot melt dispensing onto the substrate, the system removes the screen that would require cleaning and cause production interruptions, thereby improving continuity and reducing material waste.
Solution Approach 2:
The patent employs disposable dispensing tips or nozzles instead of reusable screens that require maintenance. These simple replacement components eliminate the need for frequent cleaning operations and material scrapping associated with screen degradation and clogging.
3Loss of time
If screen printing techniques are used to print PSA, then the adhesive can be applied to substrates, but air bubbles form after printing which require the printed parts to sit
Solution Approach 1:
The patent replaces screen printing with hot melt dispensing that applies adhesive directly to the substrate in a controlled manner. This substitution eliminates the trapping of air bubbles between the screen and substrate, removing the need for extended settling time and improving production cycle time.
4Ease of manufacture
If screen printing techniques are used to print PSA, then the adhesive can be applied to substrates, but the solvent presents environmental health and safety concerns with strong odors
Solution Approach 1:
The patent fundamentally changes the chemical composition parameter of the adhesive system from solvent-based to solvent-free thermoplastic. This eliminates harmful solvent vapors and odors entirely, improving worker safety and environmental conditions while simplifying the manufacturing process by removing solvent handling requirements.
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
The system reduces EHS concerns, minimizes material waste, and enhances production efficiency by reducing cycle time and maintenance, while maintaining printing quality.
Implementation Method 1
a wicking structure disposed within the support structure and configured to hold the PSA solution in place
Implementation Method 2
dispensing heads disposed within the rigid support structure and configured to deposit PSA solution on the substrate in response to applied pressure
Data Source
AI summary
A system for printing PSA on a substrate includes a rigid support structure. The system also includes a plurality of dispensing heads disposed within the rigid support structure and configured to deposit PSA solution on the substrate in response to applied pressure. Each dispensing head of the plurality of dispensing heads includes a support structure and a wicking structure disposed within the support structure and configured to hold the PSA solution, wherein the wicking structure is configured to deposit the PSA solution in a desired shape on the substrate upon contact with the substrate.