▼  Industry Background
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Optical films represent one of the segments with the highest technical barriers within the display industry supply chain. For films such as polarizers, brightness enhancement films (BEF/DBEF), diffusion films, TAC protective films, anti-reflective (AR) films, and optically clear adhesives (OCA), coating thicknesses range from tens of nanometers to tens of micrometers, with tolerances measured in nanometers. The coating fluids vary widely in viscosity, surface tension, and rheological properties—ranging from solvent-based fluids with viscosities under 10 mPa·s to OCA materials exceeding 10,000 mPa·s. Consequently, factors such as pulsation, precision, and cleanliness during pumping directly impact the optical performance and production yield of the films.

Featuring pulse-free positive displacement delivery, a repeatability of ±0.2%, and a clean, fully magnetic seal, the JONSN MPG and MRA series micro gear pumps provide a comprehensive fluid handling platform for optical film coating lines—capable of everything from precision micro-metering to stable, medium-flow fluid supply.

▼  Industry Pain Points
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▎Nanoscale Film Thickness: Pumping Pulsation Equals Defect
The thickness of a single-layer AR (anti-reflective) coating is merely 80–120 nm, while the coating thickness of the PVA dyeing layer on a polarizer must be controlled within a ±2% tolerance. Although the positive displacement principle of gear pumps is superior to that of diaphragm pumps, standard gear pumps still suffer from inter-tooth meshing pulsation; in nanoscale coating applications, even the slightest flow fluctuation translates directly into visible thickness streaks, leading to immediate rejection during in-line inspection.

▎Diverse Coating Fluids: A Single Pump Cannot Handle All
A single optical film production line may process a wide range of materials: TAC solutions (low viscosity, ~10 mPa·s), UV resins for brightness enhancement films (hundreds of mPa·s), and OCA optical adhesives (5,000–15,000 mPa·s). These fluids differ vastly in viscosity, solvent systems, and solid content; standard pumps require specific selection for each fluid type, resulting in complex spare parts management and lengthy changeover times.

▎Micro-bubbles and Particle Contamination: The Primary Enemies of Optical Films
Display films demand stringent optical-grade cleanliness; particles or bubbles larger than 50 μm can create visible dark spots after polarizer lamination, rendering the entire film sheet scrap. The three main sources of coating fluid contamination are material leaching from the pump body, debris from seal wear, and air ingress due to mechanical seal leakage.

▎Solvent-based Fluids: VOC Control and Explosion-Proof Requirements
Optical film coating processes utilize large quantities of solvents such as MEK, toluene, and ethyl acetate. Pumps must meet three critical criteria: ① fully sealed design with zero VOC leakage; ② wetted parts resistant to solvent swelling; and ③ suitability for explosion-proof zones (regarding motor and sensor selection). When pumps with mechanical seals operate in these solvents over the long term, the probability of leakage due to seal face wear increases exponentially with operating time.

▼  JONSN Solution: One Coating Fluid Circuit Platform for Six Types of Optical Films
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▎Polarizers — PVA Dyeing Layer + TAC Protective Layer
Polarizer manufacturing involves coating and lamination processes following the dyeing and stretching of PVA film. Both the PVA dyeing solution (aqueous iodine or dye solution) and the TAC protective layer coating fluid (low-viscosity solvent-based) require long-term flow stability to ensure batch-to-batch consistency in polarization degree and transmittance. The JONSN MPG series (40–80 μl/r, 1–280 ml/min) utilizes precision multi-tooth gears to effectively suppress meshing pulsation; paired with a servo motor, it achieves a repeatability of ±0.2%.

• Recommended: MPG series (1–280 ml/min); all-PEEK flow path resistant to iodine solution corrosion.

• Performance: Polarization degree fluctuation < ±0.1%; single-sheet transmittance consistency > 99.5%.

▎TAC Film — Solution Casting and Functional Coating
As the core support layer of a polarizer, TAC film is produced via a solution casting process that requires delivering a mixture of TAC, dichloromethane, and methanol to the casting die within a very narrow flow rate window. The coating fluid has a viscosity of approximately 500–2000 mPa·s; the rapid evaporation of solvents places extremely high demands on pump sealing. The MRA series (100–2000 ml/min) features a fully magnetic drive and FFKM (perfluoroelastomer) seals, ensuring zero swelling and zero leakage during long-term contact with dichloromethane.

• Recommended: MRA series (100–2000 ml/min); FFKM seals are completely inert to halogenated hydrocarbons.

• Performance: Die pressure fluctuation < ±0.5%; longitudinal film thickness uniformity R < 2%.

▎Brightness Enhancement Film (BEF/DBEF) — UV Resin Microstructure Coating
Brightness enhancement films achieve light concentration and brightness enhancement by transferring prism microstructures onto a PET base film using UV-curable resin. For UV resins with viscosities ranging from 200 to 800 mPa·s, the coating volume precisely determines the prism height (typically 10–50 μm) and the consistency of the apex angle. The MRA series utilizes positive displacement delivery to ensure the coating volume remains unaffected by batch-to-batch resin viscosity fluctuations; it achieves a flow rate accuracy of ±0.5% and controls prism height deviation to within ±0.5 μm.

• Recommended: MRA Series (100–2000 ml/min); positive displacement technology resistant to viscosity drift.

• Performance: Prism height CpK ≥ 1.67; batch-to-batch gain value deviation < ±1%.

▎Diffusion Film — Precision Feeding of Bead-Loaded Coating Fluids
Diffusion films achieve uniform light distribution by coating a base film with a resin fluid containing diffusing microbeads (PMMA, PS, or TiO₂; particle sizes of 1–20 μm). The primary challenge is pump wear caused by the particle-laden fluid; in standard gear pumps, the continuous abrasive action of the microbeads widens the clearances between bushings and gear faces, causing flow rates to deviate by more than 10% from set values within three months. JONSN pumps feature zirconia ceramic gear shafts and DLC-coated pump bodies, achieving hardness levels of 2000–3000 HV and offering wear resistance more than five times greater than that of standard stainless steel gear pumps.

• Recommended: MRA Series (zirconia gears + DLC-coated pump body).

• Performance: Flow rate drift < ±2% per year; no microbead breakage; stable batch-to-batch haze levels.

▎AR (Anti-Reflective) Film — Nanoscale Precision Multilayer Coating
AR films typically consist of 4 to 7 alternating layers of materials with varying refractive indices. Each layer ranges from 80 to 150 nm in thickness, with thickness deviation requirements of less than ±3 nm. The coating fluids used are ultra-low viscosity TEOS/TTIP sol-gel systems (< 5 mPa·s). The MPG series (displacement: 40 μl/r) utilizes precision gear meshing and a servo closed-loop drive to achieve nanoliter-level pulsation suppression; combined with flow feedback correction from an in-line film thickness gauge, it meets the extreme precision requirements for optical interference coating thicknesses.

• Recommended: MPG series (40 μl/r); dead volume < 0.5 ml, ensuring zero cross-contamination during fluid changes.

• Results: Single-layer thickness deviation < ±3 nm; batch-to-batch reproducibility of reflectance spectral curves.

▎OCA (Optically Clear Adhesive) — Continuous, Bubble-Free Coating of High-Viscosity Material
OCA is a critical material for the full lamination of touch screens and display modules; it typically features viscosities of 5,000–15,000 mPa·s and coating thicknesses of 25–175 μm. Any pulsation or air entrapment during the coating process results in visible bubble defects after lamination. The DP series (0.2–100 cc/r) employs high-strength, multi-tooth gears for positive-displacement delivery of high-viscosity materials; when paired with a vacuum degassing feed system, it enables continuous, bubble-free coating. Outlet flow remains unaffected by changes in adhesive viscosity, ensuring uniform coating thickness across the entire width.

• Recommended: DP series (0.2–100 cc/r); multi-tooth gears ensure strong intake of high-viscosity fluids.

• Results: Coating thickness uniformity (R) < 3% across the full width; bubble defect rate < 0.1%.

▼  Product Selection Quick Reference
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▼  Core Values
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▎MPG → MRA → DP: A Three-Tier Precision Matrix—One Pump for Every Film Type
Spanning from nanoscale AR films (MPG) to micron-scale OCA (DP), JONSN’s three-tier product matrix covers the entire viscosity and thickness spectrum of optical film coating. Manufacturers no longer need to source pumps from six different suppliers for six types of films.

▎Precision Multi-Tooth Meshing: Suppressing Coating Pulsation at the Source
The MPG and MRA series utilize high-tooth-count gears and precision grinding processes, reducing meshing pulsation to just one-third to one-fifth of that found in standard dual-tooth pumps. In nanoscale coating applications, this ensures that inline film thickness monitoring systems do not trigger alarms caused by pump-induced fluctuations.

▎Optical-Grade Cleanliness: Zero Metal Leaching and Zero Particle Generation
Featuring flow paths constructed entirely of PEEK and zirconia ceramic, the pumps eliminate metal ion leaching that could contaminate coating fluids. A fully magnetic seal design prevents debris shedding associated with mechanical seals, ensuring reliable long-term operation in Class 100 cleanroom environments.

▎Universal Solvent Compatibility: One Pump for the Entire Production Line
The combination of PEEK components and FFKM (perfluoroelastomer) seals offers complete inertness against solvents such as MEK, toluene, ethyl acetate, dichloromethane, and NMP, allowing a single pump model to serve the entire production line—from TAC film casting to OCA coating.

▎Ultra-Long Service Life and Low Drift: Minimizing Downtime for Online Adjustments
Equipped with zirconia ceramic gear shafts and DLC-coated pump bodies, the pumps offer 20,000 hours of maintenance-free operation. With a flow rate drift of less than 2% per year, optical film production lines avoid batch scrap caused by pump-induced thickness deviations.

▎Traceability and Process Control
Supporting Modbus and CANopen communication protocols, the pumps allow for the calibration and storage of motor speed-to-flow rate curves. Coating flow data for every roll of optical film can be traced back to real-time pump operating parameters, meeting IATF 16949 requirements for process capability analysis.