Electron beam curing and methods for transparent and colored coatings for the coil industry

Abstract

A method and apparatus are provided for electron beam (EB) curing of a roll material coated with an energy-curable resin. The apparatus includes a curing component, a microprocessor unit, one or more sensors, and a user interface. The curing component comprises a fixed portion and a movable portion. The fixed portion includes a rotating body and a first moving device. The movable portion includes an accelerator. The fixed portion and the movable portion are movably connected to each other using a connector. The connector is configured to move using a second moving device. The curing component is communicatively connected to the microprocessor unit. The roll material arrives at an input gate at the fixed portion of the curing component for curing purposes and exits through an output gate at the fixed portion of the apparatus after curing.

Description

[0001] Related applications

[0002] This application is a continuation-to-file of U.S. Application No. 18 / 477,460, filed September 28, 2023. The entire teachings of the foregoing application are incorporated herein by reference. Technical Field

[0003] The embodiments described herein generally relate to methods and apparatus for curing roll materials. More specifically, these embodiments relate to methods and apparatus for electron beam curing of transparent and colored coatings on roll materials. Background Technology

[0004] Unless otherwise specified herein, the methods described herein are not considered prior art to the claims of this application.

[0005] Steel is made of iron and has been widely used for many years in a variety of applications, including buildings, infrastructure, tools, ships, trains, automobiles, machinery, electrical appliances, weapons, and rockets. In almost all applications, steel is galvanized for further use. Some examples of galvanized steel are in the form of coils used in commercial or industrial applications. Some exemplary uses of such coils are in applications such as construction, roofing, household and office appliances, transportation, and furniture. Galvanized coils are made of steel with a layer of zinc on the surface. Galvanizing is a cost-effective method of corrosion protection and is often used to protect coils. Galvanized coils are coated with a clear or colored coating to protect the coil from environmental impacts and maintain its appearance by providing scratch and abrasion resistance. This can be achieved by roller coating or spray coating methods. Typically, the width of the coil to be coated is about 1.2 to 2.5 meters, and coating is carried out in a continuous process at a speed of 90 to 150 meters per minute. The thickness of the coating or paint varies depending on the application, ranging from 100 micrometers to 150 micrometers. Once the coil is coated, it needs to be dried in a dryer. Typically, drying tunnels are used to dry coated roofing membranes. These tunnels are several meters long and function as long drying ovens. The roofing membrane to be coated is introduced into the drying tunnel. In addition to the membrane, the tunnel carries approximately 50% to 70% by weight of water or solvent. Therefore, preparing the membrane in the drying tunnel can take a considerable amount of time. The coating used typically contains 30% solids. Consequently, coating the membrane results in a dry film thickness of approximately 30 to 45 micrometers. Furthermore, drying the coating is a lengthy process. Such processes require long ovens that supply hot air heated by natural gas. These processes result in a very high carbon footprint and may therefore violate sustainability requirements.

[0006] The introduction of energy-curing resins in the field of coil coatings has reduced energy consumption by nearly nine times compared to solvent- or water-based systems. Energy-curing resins are available as 100% solids containing monomers or oligomers and require electrons or photons. Some examples of such systems are ultraviolet (UV) curing systems and electron beam (EB) curing systems. In UV curing systems, the energy-curing resin requires photons generated by UV rays in the presence of a photoinitiator, while in EB curing systems, electrons are created by an electron beam (EB) accelerator. Electrons have sufficient ionization potential to initiate free radicals and propagate the polymerization reaction without the need for a photoinitiator. Conventional coatings used for curing contain approximately 30% to 50% solids and require a long drying time in large dryers, while EB curing is 100% solids. The energy required for EB curing is approximately 10% to 20% of the total energy required for conventional solvent / water-based coatings. EB curing is preferred for coil coating applications. Typically, EB curing systems include a movable and stationary self-shielding structure, an EB accelerator, and a high-voltage source.

[0007] In the curing process, the roll material to be coated first needs to be coated with an energy-curable resin. The roll material is a long sheet of galvanized steel, and the coating process is continuous. It involves splicing rolls of material one after another to connect two or more rolls for the coating process. The interconnection or splicing of two rolls of material results in a joint with width. This width typically varies between 30 mm and 50 mm. The roll of material with the interconnecting joint needs to pass through the EB accelerator for EB curing. The joint is wider than the entrance area of ​​the EB accelerator. Therefore, as the joint approaches the EB accelerator, the EB accelerator's movable self-shielding opens, creating the necessary space for the joint to pass through. During this period, the beam, nitrogen injection, and the voltage of the EB accelerator are all shut off, which in turn causes the curing process to stop. Because the roll material to be cured continues to pass through the EB accelerator continuously when these parameters are off, a certain amount of roll material passes through the equipment uncured. Therefore, such roll material is wasted.

[0008] Therefore, there has been a long-standing but unresolved need for improved equipment and methods for coil curing that result in less steel coil waste. Summary of the Invention

[0009] Although the ways in which this disclosure addresses the shortcomings of the prior art will be discussed in more detail below, in general, this disclosure provides a device that can be attached to a vehicle for lifting objects.

[0010] The purpose of this disclosure is to provide an apparatus for curing roll materials using electron beam (EB).

[0011] Another objective of this disclosure is to provide a device that minimizes roll material waste during curing.

[0012] Another object of this disclosure is to provide a method for electron beam (EB) curing of a roll material coated with an energy-curable resin.

[0013] Another objective of this disclosure is to provide a curing method that achieves less waste of roll material.

[0014] Another objective of this disclosure is to provide a curing method for rapidly achieving steady-state conditions.

[0015] Another objective of this disclosure is to provide a more efficient method.

[0016] The apparatus according to this disclosure may include a curing assembly for curing using an electron beam (EB), a microprocessor unit, a user interface, and one or more sensors. Further, the curing assembly may include a stationary portion and a movable portion. The stationary portion may include an input gate for feeding the roll to be cured and an output gate for the cured roll to exit. The apparatus may further include a processing zone between the input gate and the output gate. The processing zone may include one or more injection elements for injecting nitrogen gas. The processing zone may include an emission zone. The emission zone may be defined as the area in the processing zone where electrons are emitted onto the roll. In other words, the emission zone corresponds to the area where the roll is cured. The stationary portion may further include a rotating body. The rotating body may be configured to rotate using a first moving device.

[0017] In one embodiment, the fixed portion and the movable portion can be coupled to each other via a connector. The movable portion can be configured to be displaced relative to the fixed portion using a second moving device. The movable portion may include an accelerator. The accelerator can be configured to emit electrons onto the roll for curing. The accelerator may include a chamber, a window, and a foil. The chamber may include multiple components. The multiple components of the chamber may include a repulsion plate, an electron gun assembly, and a filament. The accelerator can be configured to provide a high-intensity electron beam to the roll using the electron gun assembly and the filament. The repulsion plate can be configured to repel electrons bounced back into the chamber. The high-intensity electron beam travels through the window and through the foil to impact and be absorbed into the roll for curing.

[0018] In this implementation, the microprocessor unit can be configured to control the operation of the device by sending and receiving signals corresponding to voltage, beam current, rotating body, connector, and nitrogen and oxygen concentrations. One or more sensors can be configured to monitor the concentrations of nitrogen and oxygen in the processing area. A user interface is available for user access to control the operation of the device.

[0019] The method according to this disclosure may include two phases: a first phase corresponding to normal operation and a second phase corresponding to connector operation. In normal operation, a microprocessor unit may be configured to generate a first set of signals. In an exemplary embodiment, the first set of signals may include a first velocity signal, a first displacement signal, a first beam signal, and a first concentration signal. The first set of signals may be transmitted to a curing assembly for normal operation. In an embodiment, during normal operation, the roll material to be cured enters at a processing zone at a first velocity, a movable portion is placed at a first position, the nitrogen concentration is at a first level, and the beam is turned on. These conditions provide curing of the roll material with the electron dose required for curing.

[0020] In the second operating phase, the method may include a step of detecting the arrival of the connector. The connector is part of a roll of material, wherein the end of a first roll is attached or connected to the starting end of a second roll. Typically, the thickness of the roll increases in the section with the connector. When the connector reaches the input gate of the device, one or more signals are generated and transmitted to the microprocessor unit. The microprocessor unit may generate a second set of signals upon the arrival of the connector. The second set of signals may include a second velocity signal, a second beam signal, a second concentration signal, and a second displacement signal. In the second operating phase, the speed of the rotating body changes to a second velocity, the beam is shut off, the nitrogen concentration is brought to a second level, and the movable portion is displaced to a second position. In one embodiment, the microprocessor unit may receive a signal indicating that the connector has passed through the processing area via a user interface. In another embodiment, the microprocessor unit may automatically generate one or more signals for bringing the device into steady-state conditions. Accordingly, normal operation of the device resumes after the connector has passed through the processing area. Attached Figure Description

[0021] The above and other features of this disclosure will become more fully apparent from the following description taken in conjunction with the accompanying drawings and the appended claims. It should be understood that these drawings depict only a few embodiments according to this disclosure and should not be construed as limiting its scope, as the disclosure will be described more specifically and in detail using the drawings, in which: Figure 1 An exemplary block diagram representation of an apparatus for curing roll material using electron beam (EB) according to this disclosure is shown schematically; Figure 2A An exemplary flowchart of the first operational phase of a method for curing roll material according to this disclosure is shown; Figure 2B An exemplary flowchart of the second operational phase of a method for curing roll material according to this disclosure is shown; Figure 3A cross-sectional view of a curing component of an exemplary device for curing roll material, in a first position during a first operation phase, is schematically shown according to this disclosure. Figure 4 A cross-sectional view schematically illustrates a curing assembly of an exemplary apparatus for curing roll material in a second position during a second operation phase, according to this disclosure; and Figure 5 An exemplary connector of a proximity device according to this disclosure is schematically shown, as well as the variation in roll thickness when the connector is present. Detailed Implementation

[0022] The embodiments detailed herein are best understood with reference to the accompanying drawings and descriptions. All aspects of the embodiments described herein will be better appreciated and understood when considered in conjunction with the following description and drawings. However, it should be understood that while the following description points to preferred embodiments and their numerous specific details, it is given by way of illustration rather than limitation. Many changes and modifications can be made within the scope of these embodiments without departing from the spirit and scope of this document, and all such modifications are included in the embodiments herein.

[0023] As used herein, the terms “exemplary” or “illustrative” mean “serving as an example, instance, or illustration.” Any implementation described herein as exemplary or illustrative is not necessarily to be construed as advantageous or preferred over other implementations. Unless the context requires otherwise, throughout the description and claims, the word “comprising” and its variations, such as “including” and “containing,” should be interpreted in an open, inclusive sense, meaning “including but not limited to.”

[0024] This disclosure generally relates, and in particular, to methods, apparatus, systems, and devices for the continuous processing of roll materials using energy-curing resins via electron beams (EB).

[0025] Reference Figure 1 The disclosure provides an exemplary block diagram of an apparatus 100 for curing roll material using electron beam (EB) according to the present disclosure. The roll material is referred to as a long metal sheet and is in the form of a roll. Typically, such a roll is 1.2-2.5 meters wide and has a thickness of approximately 1.5 to 2.5 millimeters. To make the curing operation a continuous process, two or more such rolls are joined together.

[0026] To cure this roll material, device 100 may include a curing assembly 106, a microprocessor unit 108, one or more sensors (not shown), and a user interface 110. The curing assembly 106 may be configured to perform curing on the roll material coated with an energy-curable resin. The curing assembly 106 may include a stationary portion 102, a movable portion 104, and a processing area (not shown) therein. In one embodiment, the stationary portion 102 may be configured to be stationary and may include a rotating body 306, an input gate 302, and an output gate 304 (see [link to documentation]). Figures 3 to 4 ).

[0027] See also Figures 3 to 4 The input door 302 can be configured to receive the roll material to be cured, and the output door 304 can be configured to output the roll material that has been cured from the device 100. The roll material to be cured is wound on the rotating body 306. Therefore, during the curing operation, the roll material enters through the input door 302, is wound on the rotating body 306, and exits through the output door 304.

[0028] In one embodiment, during the curing operation, the rotating body 306 can be rotated using a first moving device (not shown). The first moving device can be configured to rotate the rotating body 306 at different speeds. In one embodiment, the first moving device can be configured to change the speed of the rotating body 306 from a first speed to a second speed. In another embodiment, the first moving device can be configured to change the speed of the rotating body 306 from a second speed back to a first speed.

[0029] The rotating body 306 can be configured to carry the roll material from the input gate 302 through the processing zone of the curing assembly 106 to the output gate 304. The rotating body 306 can be water-cooled to neutralize the roll material and reduce thermal effects during curing. Curing of the roll material occurs in the processing zone. The gap H at the entrance of the processing zone (see...) Figure 5 The gap is a predefined fixed gap used to facilitate the entry of the roll material 312 into the processing zone. In this embodiment, such a gap is 51.4 mm. Curing may include various steps, such as feeding the roll material, providing an inert environment to the roll material, maintaining the oxygen concentration at a predefined level, emitting electrons, and providing coolant to the roll material via the rotating body 306 during curing. The step of providing an inert environment may include injecting nitrogen and maintaining the nitrogen concentration within the processing zone. The processing zone may include an emission zone. The emission zone can be defined as the area within the processing zone where electrons are emitted onto the roll material. In other words, the curing of the roll material takes place in the emission zone.

[0030] In one embodiment, the movable portion 104 may be configured to shift relative to the fixed portion 102 using a connector 308. The device 100 may include a second moving mechanism to shift the movable portion 104 relative to the fixed portion 102. In one embodiment, the movable portion 104 may be configured to move between a first position and a second position. In another embodiment, the movable portion 104 may be configured to move between a plurality of different positions.

[0031] In one embodiment, the movable portion 104 includes an accelerator 310. The accelerator 310 can be configured to emit electrons to cure the roll material. In another embodiment, the accelerator 310 may include a chamber, a window, and a foil 316. The chamber may be configured to surround a plurality of components therein. These components may include a repulsion plate, an electron gun assembly, and a filament. The electron gun assembly, combined with the filament, can be configured to generate a high-intensity electron beam using a high voltage. The repulsion plate can be configured to repel electrons bounced back into the chamber. The window is the only opening in the chamber for venting the electron beam to the outside. The beam current is generated in relation to the high voltage applied to the electron gun assembly. The foil 316 is placed adjacent to the window to allow the electron beam to pass through. The coated roll material is placed in front of the foil 316 for curing.

[0032] In embodiments of this disclosure, the movable portion 104 can be configured to be in a first position and can be displaced relative to the fixed portion 102 to a second position. In the first position, a first gap D1 is created between the roll and the foil 316 (see...). Figure 3 In an exemplary embodiment, the first gap D1 is approximately 20 mm. In some embodiments of this disclosure, the first gap D1 is adapted for the roll 312 to pass through the treatment area for curing.

[0033] After the movable portion 104 moves from the first position to the second position, a second gap D2 is created between the roll and the foil 316 (see...). Figure 4 In an exemplary embodiment, the second gap D2 is approximately 70 mm. It should be noted that the values ​​of the first gap D1 and the second gap D2 are exemplary and can vary according to the requirements of different devices without departing from the scope of the invention.

[0034] In some embodiments of this disclosure, an electron gun assembly and a filament are required to generate a high-intensity electron beam to cure a roll-to-roll material coated with an energy-curable resin. The high-intensity electron beam is generated by applying a high voltage to the electron gun assembly, thereby obtaining the beam current required for curing the roll-to-roll material.

[0035] Reference Figure 1In an exemplary embodiment, the curing assembly 106 may be communicatively connected to the microprocessor unit 108. The microprocessor unit 108 may be configured to monitor and control the operation of the curing assembly 106 and the device 100 for curing the roll material.

[0036] In embodiments of this disclosure, nitrogen gas is injected into the processing zone. The processing zone may include one or more injection elements (not shown) for injecting nitrogen gas. One or more injection elements may be configured to maintain the nitrogen concentration within a predefined concentration limit. In an exemplary embodiment, the predefined concentration limit may be within 100 to 150 ppm. In a further embodiment, the oxygen concentration may be configured to be maintained below a certain level. In an exemplary embodiment, the oxygen concentration level may be below 150 ppm. Such an oxygen concentration helps to reduce the inhibitory effect on free radicals responsible for propagating the polymerization reaction.

[0037] One or more sensors can monitor the concentrations of nitrogen and oxygen. For this purpose, one or more sensors can be configured to measure the concentrations of nitrogen and oxygen. In one embodiment, such measurements can be performed periodically. In another embodiment, such measurements can be performed continuously. One or more sensors can transmit the measured nitrogen and oxygen concentrations to microprocessor unit 108 for further processing.

[0038] In one embodiment, the microprocessor unit 108 may be communicatively connected to the user interface 110. In another embodiment, the user interface 110 may be an input interface and may be configured to receive one or more inputs during the curing process. In yet another embodiment, the user interface 110 may be an output interface and may be configured to display one or more parameters during the curing process.

[0039] In some exemplary embodiments of this disclosure, the user interface 110 may be configured to display the voltage applied to the device 100, the beam current, the concentrations of nitrogen and oxygen in the device 100, etc.

[0040] In other embodiments of this disclosure, the user interface 110 may be configured to receive inputs for controlling the voltage value, beam current, desired nitrogen and oxygen concentrations, etc., of the curing process.

[0041] In some embodiments of this disclosure, the user interface 110 may be configured to receive input to control the operation of the rotator 306 and send the received input to the microprocessor unit 108. Based on the received input, the microprocessor unit 108 controls the operation of the rotator 306 by supplying power to the first moving device.

[0042] In other embodiments of this disclosure, the microprocessor unit 108 may be configured to detect when the values ​​of any one of the voltage, beam current, nitrogen, and oxygen concentrations exceed a corresponding predefined range. The microprocessor unit 108 may instruct the user interface 110 to generate an alarm. The generated alarm may be an audio alarm, a video alarm, or a combination thereof.

[0043] In some embodiments of this disclosure, the operation of device 100 can be controlled by a user. For example, if the value of any one of the voltage, beam current, or nitrogen and oxygen concentration exceeds its predefined corresponding range, the user can directly shut down device 100 by turning off the power supply to device 100.

[0044] In other embodiments, device 100 may include a power off switch to shut down device 100 in the event of an alarm. This power off switch may be user-operated to shut down device 100.

[0045] In some exemplary embodiments of this disclosure, the first moving device and the second moving device may be a motor for rotating the rotating body 306 and for displacing the movable portion 104 of the curing assembly 106, respectively.

[0046] In an embodiment, device 100 may include one or more means for preventing nitrogen from being discharged from the processing area of ​​device 100.

[0047] The curing component 106 may include two locations during operation, such as Figure 3 The first position seen and as Figure 4 The second position is as seen. The first position is achieved during the first operation phase, and the second position is achieved during the second operation phase.

[0048] Referring to Figure 2, an exemplary flowchart of a method 200 for curing roll materials according to the present disclosure is disclosed. It should be noted that this method can... Figure 1 Executed on publicly available device 100.

[0049] In one embodiment, the method 200 for curing the roll material using the device 100 may include two stages: a first stage indicating normal operation and a second stage indicating joint operation. In one embodiment, the roll material 312 coated with an energy-curable resin is being cured by the device 100.

[0050] In the first phase or normal operation, the method may include an initial step of starting the device 100 by providing a voltage. The method may further include the step of injecting nitrogen and maintaining the nitrogen concentration at a predefined level. In this embodiment, the predefined level of nitrogen concentration is 100 to 150 ppm.

[0051] In step 202, the method includes generating a first set of signals by the microprocessor unit 108 for operation of the device 100 in a first phase. The first set of signals may include a first velocity signal for rotating the rotating body 306 at a first speed, a first displacement signal for holding the movable portion 104 of the curing assembly 106 at a first position, a first beam signal for generating an electron beam of a first value, and a first concentration signal for maintaining the nitrogen concentration in the processing zone at a first concentration level. The microprocessor unit 108 may transmit the generated first set of signals to corresponding components. For example, the first velocity signal is transmitted to a first moving device for rotating the rotating body at a first speed. In an embodiment, the first speed is 100 meters per minute. The first displacement signal is transmitted to a second moving device for maintaining the position of the movable portion at the first position. The first beam signal is transmitted to the accelerator 310 for generating a beam of a first value. The first concentration signal is transmitted to one or more injection elements for maintaining the nitrogen concentration at a first concentration level.

[0052] In step 204, method 200 may include receiving at least one end of the roll 312 to be cured at the input gate. The direction in which the roll 312 enters the device 100 is indicated by A (see...). Figure 1 and Figures 3 to 4 In step 206, the microprocessor unit 108 may receive signals related to the roll material, and the microprocessor unit 108 determines the arrival of the connector based on the received signals. If the arrival of the connector is not determined, the method continues in the first stage in steps 208-210. If the arrival of the connector is determined, the second stage of the method is executed in steps 252-260, by... Figure 2B The X indicator in the text.

[0053] If no arrival of the connector is detected, the first operation continues to step 208. In step 208, the roll material reaches the emission zone, where the accelerator 310 emits electrons onto the roll material for curing. In the emission zone, as discussed above, the gap between the roll material 312 and the foil 316 is a first gap D1. In embodiments, the first gap D1 is approximately 20 mm. In some embodiments of this disclosure, the first gap D1 is adapted to allow the roll material 312 to pass through the processing zone for curing. When a high voltage of 125 to 150 kV is applied to the electron gun assembly, a high-voltage electron beam is generated by the electron gun assembly and the filament, resulting in the emission of a high electron beam, which corresponds to a high beam current. The roll material 312 reaching in front of the foil 316 is provided with a high beam current by the accelerator 310. The high-intensity electron beam provides the dose required for curing the roll material 312. In embodiments, the dose is defined as the energy absorbed per unit mass and is measured in megarads (Mrad). In an exemplary embodiment, the dose provided for curing is approximately 50 kGy. The dose is dependent on the production line speed. In other words, the dosage is linked to the production line speed and controlled based on the production line speed through the following relationship:

[0054] Where D is the dose in kGy. I is the beam current measured in mA. V is the product speed in meters per minute. k is a scaling factor in units of kGy / mpm / mA.

[0055] After the curing of the roll material in the launch area is completed, a cured roll material 314 is generated. The cured roll material 314 moves toward the output door 304 to leave, as shown in step 210. The direction in which the cured roll material 314 leaves the device 100 is indicated by B (see [reference]). Figure 1 and Figures 3 to 4 ).

[0056] Returning to step 206, if the arrival of the joint is detected, the second operation phase is executed. The second phase corresponds to the joint operation, where the joint arrives at input gate 302 of device 100. As explained above, a joint is the portion of a roll of material where two rolls are joined together. Figure 5 An exemplary connector 502 at the input gate 302 of the device 100 and the variation in the thickness of the roll 312 affected by the connector 502 are illustrated. During the curing operation, the thickness E of the portion of the roll 312 with the connector 502 is approximately 50 mm, and the length F of such connector 502 is approximately 300 mm to 500 mm.

[0057] In the second stage, the microprocessor unit 108 may receive a connector signal indicating the arrival of connector 502 in step 252. In one embodiment, the microprocessor unit 108 may receive the connector signal from a connector detector (not shown). In another embodiment, a user may provide the connector signal to the microprocessor unit 108 using a user interface 110. In yet another embodiment, the device 100 may include a first switch to indicate the arrival of connector 502 at input gate 302. The first switch may be user-operated. Upon receiving the connector signal, the microprocessor unit 108 generates a second set of signals in step 254. The second set of signals is transmitted to the curing assembly 106 for connector operation. The second set of signals may include a second velocity signal, a second beam signal, a second displacement signal, and a second concentration signal. As connector 502 enters the processing area of ​​device 100 through input gate 302, the second velocity signal is received by a first moving device to change the speed of the rotating body 306 from a first speed to a second speed. In an exemplary embodiment, the second speed of the rotating body 306 is 50 m / min.

[0058] In step 256, the beam is shut off based on the second set of signals, more specifically based on the second beam signal. In step 258, a second concentration signal is transmitted to the injection element to change the nitrogen concentration in the treatment zone from a first level to a second level. The second level indicates a higher concentration than the first level. The first level corresponds to a concentration in the range of 100 to 150 ppm. A second displacement signal is transmitted to the second moving device to displace the movable portion 104 relative to the fixed portion 102. In an embodiment, based on the second displacement signal, the movable portion 104 of the curing assembly 106 is displaced from a first position to a second position. The second position of the movable portion 104 is a predefined distance C, i.e., 50 mm, from the fixed portion 102. The second position of the movable portion 104 displaces the foil 316 of the accelerator 310 from the roll to obtain, as Figure 4 The second gap D2 is shown. In other words, a second gap D2 is created in the emission zone. In this embodiment, the second gap D2 is approximately 70 mm. Due to this second gap D2 in the emission zone, the connector 502, with a width between 30 and 50 mm, can easily pass through the emission zone.

[0059] In step 260, it is detected that connector 502 has exited through output gate 304 of device 100. The exit of the connector indicates that a second or new roll of material has been configured for curing using device 100. In one embodiment, microprocessor unit 108 may receive a departure signal indicating that connector 502 has exited device 100. In another embodiment, the microprocessor may wait for a predefined time for connector 502 to exit. An example of such a predefined time is 3.5 seconds. In yet another embodiment, device 100 may include a second switch for indicating the exit of connector 502. The second switch may be user-operated. In one embodiment, device 100 may include a single switch that functions as both a first and a second switch to indicate the arrival or departure of connector 502.

[0060] In step 262, after connector 502 passes through device 100, microprocessor unit 108 can resume the first operating phase. In other words, the method jumps to step 202. Accordingly, microprocessor unit 108 can generate a first set of signals for device 100 to operate under the first phase or normal conditions.

[0061] The generated first set of signals can be transmitted to the corresponding components of the curing assembly 106 to restore normal operation. The movable part 104 is moved from the second position to the first position via a first moving device. The rotating body 306 is rotated at a first speed by the first moving device. The beam is turned on, and the nitrogen concentration is brought from the second level to the first level through the injection element. Accordingly, normal curing operation performed by the device 100 is resumed.

[0062] Therefore, in the second stage or connector operation, only the beam is shut off. Other parameters, such as inerting with nitrogen or high voltage, remain on. Thus, to achieve steady-state conditions after the second stage, only the beam needs to be turned on. In other words, device 100 can quickly achieve steady-state conditions using the method described above. Steady-state conditions refer to conditions where the device operates in its normal phase without any specific changes in any parameters. In this embodiment, the time required for device 100 to change from the second operating phase to the first operating phase, or the time required to achieve steady-state conditions after the second stage, is approximately 3.5 seconds, which is significantly reduced compared to existing times.

[0063] It should be noted that although specific steps are disclosed in this method, one or more steps may be separated or combined without departing from the scope of this disclosure.

[0064] In some embodiments of this disclosure, device 100 communicates with an automated winding and splicing system for continuously supplying rolls of material to device 100. Further, the automated winding and splicing system is configured to form a joint with two rolls of material at a time. When the first roll being processed by device 100 is nearing completion, the automated winding and splicing system provides a joint between the first and second rolls of material to device 100.

[0065] In some embodiments of this disclosure, the method for coating the coil is any one of galvanizing, roll coating, electrochemical coating, vapor deposition, conversion coating, or thermal spraying.

[0066] In some embodiments of this disclosure, a roll coating apparatus 100 is placed prior to the apparatus 100 for coating roll materials. The coating head in the roll coating apparatus 100 is configured to coat the roll material before it enters the apparatus 100.

[0067] In some embodiments of this disclosure, when the connector 502 arrives, a user of the user interface 110 can stop the coating operation.

[0068] Therefore, this invention offers advantages over existing technologies in reducing roll material waste. In existing technologies, device 100 is shut down when connector 502 arrives. Specifically, the beam current, high voltage, and nitrogen injection are stopped. Consequently, more time is required to open all components and allow the device to achieve steady-state operation after connector 502 has passed. In other words, the time required to achieve steady-state conditions using this existing method while the roll material is rotating is up to 30 seconds. This results in roll material waste because device 100 takes a considerable amount of time to start up and achieve the beam current required to deliver the dose for curing. In this case, at a speed of 50 m / min, the total waste per roll is approximately 25 to 30 meters. For an 8-hour shift, the estimated waste is 120 linear meters (LM) per shift. This disclosure is advantageous in providing device 100 with faster processing times. The time required for device 100 to restart and deliver the dose for curing to the roll material is less. The estimated restart time for device 100 after connector departure is only 3.5 seconds. Uncoated roll material waste is less than 3 LM. For an 8-hour shift, at a speed of 50 meters per minute, the waste per roll is less than 12 LM. Therefore, the waste generated per shift from uncoated and uncured rolls is reduced by nearly 10 times.

[0069] All scopes referenced herein should be considered inclusive unless otherwise stated. Although this specification has described certain preferred embodiments, various features of different embodiments can be combined to form additional embodiments not explicitly described. Furthermore, other embodiments that will be apparent to those skilled in the art upon reading this disclosure are also within the scope of this specification. Moreover, not all features, aspects, and advantages are necessary for practicing the invention. Therefore, while the above detailed description has shown, described, and pointed out novel features applicable to various embodiments, it should be understood that those skilled in the art can make various omissions, substitutions, and changes to the form and details of the described apparatus or process without departing from the spirit of the invention. The above embodiments should be considered in all respects as illustrative only and not in any way limiting. The scope of the invention is defined by the following claims and understood in conjunction with the foregoing description.

Claims

1. A method for curing roll material, the method being performed on an electron beam apparatus having an input gate and an output gate, the method comprising the following steps: At least one roll of material is received at the input gate; The rotating body is used for curing the roll material; Confirm the arrival of the connector; Emitting electrons to cure at least a portion of the roll material; as well as The cured roll material is output from the output gate.

2. The method according to claim 1, wherein, The steps to determine the arrival of the connector include: Receive a connector signal indicating the arrival of the connector, which is a common part between the first roll and the second roll; Upon receiving the connector signal, at least one parameter of the device is changed from a first setting to a second setting; Allow the connector to pass through the launch area; and The connector is output from the output gate.

3. The method according to claim 2, wherein, The step of changing at least one parameter of the device from a first setting to a second setting after receiving the connector signal includes changing the speed of the rotating body from a first speed to a second speed.

4. The method according to claim 2, wherein, The step of changing at least one parameter of the device from a first setting to a second setting after receiving the connector signal includes changing the position of the movable part of the electron beam device from a first position to a second position.

5. The method according to claim 4, wherein, The second position of the movable part is at a predefined distance from the fixed part of the electron beam device.

6. The method according to claim 4, wherein, The second position of the movable portion displaces the foil of the accelerator from the roll to obtain a second gap in the launch zone.

7. The method according to claim 6, wherein, The second gap is approximately 70 mm.

8. The method according to claim 2, wherein, The step of changing at least one parameter of the device from a first setting to a second setting after receiving the connector signal includes changing the beam signal configured to control the electron beam, the beam signal being changed from a first beam signal to a second beam signal.

9. The method according to claim 8, wherein, The second beam signal is configured to shut down the electron beam.

10. The method according to claim 2, wherein, The step of changing at least one parameter of the device from a first setting to a second setting after receiving the connector signal includes changing the concentration level of nitrogen in the processing area from a first concentration level to a second concentration level.

11. The method according to claim 10, wherein, The second concentration level is higher than the first concentration level.

12. The method according to claim 10, wherein, The first concentration level is in the range of 100 ppm to 150 ppm.

13. The method according to claim 2, wherein, The step of changing at least one parameter of the device from a first setting to a second setting after receiving the connector signal is executed by the microprocessor.

14. The method according to claim 2, wherein, The connector signal is received from the connector switch.

15. The method of claim 1, further comprising determining the departure of the connector.

16. The method according to claim 15, wherein, The step of determining the departure of the connector includes waiting for a predefined time.

17. The method according to claim 16, wherein, The predefined time is 3.5 seconds.

18. The method according to claim 15, wherein, The step of determining the departure of the connector includes receiving a second connector signal indicating the departure of the connector.

19. The method according to claim 18, wherein, The second connector signal is received from the switch.

20. The method according to claim 18, further comprising: Upon receiving the second connector signal, at least one parameter of the device is changed from the second setting to the first setting.

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