A roll-to-roll coating drying apparatus

Abstract

The application discloses a kind of roll-to-roll coating drying device, the device includes;Drying unit, first feeding unit, first tension maintaining unit, second feeding unit, solution coating unit, total control unit, first clamping unit, second tension maintaining unit, third feeding unit, visual identification mark waste unit.First feeding unit can realize the automatic uniform speed unwinding of roll material;Solution coating unit can realize the automatic coating of detection solution;Drying unit can realize the automatic drying of coated roll material;Third feeding unit can realize the winding after deviation correction according to predetermined track to the roll material after drying;First tension maintaining unit and second tension maintaining unit can adjust the tension of roll material, avoid material to be excessively pulled;First clamping unit can realize the stable clamping feeding of roll large board, and compatible hard material feeding requirement.The device can realize the automatic feeding of multiple roll materials, automatic buffer tension, automatic solution coating, automatic visual identification mark waste verification, material automatic drying, automatic deviation correction winding and other functions.

Description

Technical Field

[0001] This technical solution mainly involves the fields of "automatic production technology of in vitro diagnostic test strips", "automatic coating and drying of roll materials", and "automatic control technology", and in particular, it relates to a roll-to-roll coating and drying device. Background Technology

[0002] In modern industrial production, roll-to-roll processing technology is widely used in the processing of various materials, especially in the field of biomaterials, due to its continuous operation and high efficiency. However, traditional roll-to-roll processing equipment has many shortcomings when processing biomaterials, particularly in the processes of film coating, gold spraying, and drying. These devices often fail to achieve precise material control and efficient drying, resulting in low production efficiency and unstable product quality.

[0003] Traditional roll-to-roll processing equipment often suffers from material slippage or tearing during unwinding and rewinding due to a lack of precise tension control and feeding mechanisms. This affects the accuracy of dicing or gold spraying and ultimately, product quality. Furthermore, these machines lack precise position adjustment capabilities in the dicing and gold spraying stages, hindering linear dicing and large-area gold spraying, thus limiting processing flexibility and precision. In the drying stage, traditional equipment typically employs a single hot air drying method, lacking precise control over humidity and temperature, resulting in unsatisfactory drying effects and potentially damaging the material.

[0004] In the biosol coating process, traditional equipment often fails to achieve precise solution delivery and uniform coating, resulting in uneven solution distribution on the material surface, which affects subsequent processing and product performance. Furthermore, these devices are inadequate in visual recognition and defect detection, unable to accurately identify and mark material defects during high-speed operation, leading to defective products entering the market and impacting corporate reputation and economic benefits.

[0005] In summary, traditional roll-to-roll processing equipment has significant disadvantages in key stages such as unwinding, film marking and gold spraying, drying, and bio-solution coating, failing to meet the demands of modern industrial production for high-efficiency, high-precision, and high-quality processing. Therefore, developing a novel roll-to-roll film marking, gold spraying, and drying equipment, along with its stable operation and efficient drying methods, is of great significance for improving the processing efficiency and product quality of biomaterials. Summary of the Invention

[0006] Based on this, this technical solution mainly solves the following problems: 1) Traditional roll-to-roll processing equipment lacks precise tension control and feeding mechanisms during unwinding and rewinding, leading to material slippage or pulling, affecting processing accuracy and product quality; 2) Existing equipment lacks precise position adjustment capabilities in the dicing and gold spraying stage, failing to guarantee linear dicing and large-area gold spraying accuracy, limiting processing flexibility and precision; 3) Traditional equipment typically uses a single hot air feeding drying method in the drying stage, lacking precise control over humidity and temperature inside the chamber, resulting in unsatisfactory drying effects and potentially damaging the materials; 4) Existing equipment cannot achieve precise solution delivery and uniform coating in the bio-solution coating stage, leading to uneven solution distribution on the material surface, affecting subsequent processing and product performance; 5) Traditional equipment has shortcomings in visual recognition and defect detection, failing to accurately identify and mark material defects during high-speed operation, resulting in defective products entering the market, affecting corporate reputation and economic benefits.

[0007] The purpose of this invention is to overcome the shortcomings of the prior art and provide a roll-to-roll coating and drying device. This roll-to-roll coating and drying device features automatic coating of rolled materials, automatic identification of waste materials after coating, and automatic drying and rewinding of materials.

[0008] To solve the above-mentioned technical problems, the objective of this invention is achieved as follows:

[0009] The present invention provides a roll-to-roll coating and drying device, including a drying unit, a first feeding unit, a first tension maintaining unit, a second feeding unit, a solution coating unit, a main control unit, a second tension maintaining unit, a third feeding unit, and a visual identification waste marking unit.

[0010] The drying unit includes a first temperature control component, an air circulation supply component, a drying component, a second temperature control component, a humidity control component, an air speed control component, and a main control component. As a processing unit after the rolled material is wrapped, the drying unit can achieve constant temperature, air speed, and humidity control for the rolled material.

[0011] Furthermore, the first temperature control component can adjust the output power of the heating element based on the feedback value of the temperature sensing element, thereby regulating the temperature inside the oven in real time; the air circulation supply component includes bottom air outlets and air outlets on the surface of the hollow roll, allowing hot air to be dispersed into the drying zone; the air circulation supply component also includes a circulating fan, enabling convenient adjustment of the hot air inside the oven, and can adjust the output air volume of the circulating fan element based on the feedback value of the internal and external pressure difference sensing element or the wind speed sensing element to meet the circulation requirements of the heated hot air; the material conveying element in the drying component ensures uniform drying of the rolled material; the second temperature... The temperature control component is located inside the drying component and can provide continuous radiant heat for the rolled material; the humidity control component can adjust the air volume at the exhaust component based on the feedback value of the humidity sensor element, and cooperate with the air circulation supply component to remove moisture from the drying component; the wind speed control component can provide real-time feedback of the wind speed value in the drying component to the main control component, and adjust the wind speed supplied by the air circulation supply component according to the characteristics of the material to be dried; the main control component can control the first temperature control component, the air circulation supply component, the drying component, the second temperature control component, and the humidity control component based on the real-time detection values ​​of each sensor element.

[0012] The first tension maintaining unit is provided with at least one adjustable gravity swing arm component and one feedback component, which can adjust the feeding speed through the swing arm position alarm;

[0013] Furthermore, when the first tension maintaining unit is used for tension adjustment of the NC membrane without a backing, it is also provided with a sliding component and a swing arm limiting component. The sliding component is used for tension adjustment of the NC membrane without a backing, and the swing arm limiting component can be a sensor or an encoder.

[0014] The second feeding unit is located after the first tension maintaining unit and can achieve stable and uniform feeding of flexible materials through a wrapping mode;

[0015] The solution coating unit is located to the right of the first tension maintaining unit, and the solution coating unit includes a coating head component containing an air nozzle element and a solution injection nozzle element;

[0016] Furthermore, the solution coating unit also includes a first position adjustment component and a second position adjustment component. The coating head component can be precisely positioned by the first and second position adjustment components to coat at least one hydrophilic material. The first position adjustment component includes a first coarse adjustment scale element and a first fine adjustment screw head element. The second position adjustment component includes a second coarse adjustment element and a second fine adjustment screw head element. The coating head component is located on the first position adjustment component and contains a self-cleaning air nozzle element and a non-contact spray head element. The self-cleaning air nozzle element has a self-cleaning module, which can realize convenient and automatic cleaning of the inside of the air nozzle. It is equipped with a vertically adjustable steel needle head, which can realize non-contact spraying of materials.

[0017] The main control unit is connected to the first feeding unit, the first tension maintaining unit, the second feeding unit, and the solution coating unit, and is used to control the operation of the first feeding unit, the first tension maintaining unit, the second feeding unit, and the solution coating unit.

[0018] The second tension maintaining unit is located after the solution coating unit and is symmetrically arranged with the first tension maintaining unit.

[0019] The third feeding unit is located at the tail end of the equipment, and its front end is equipped with a second tension maintaining unit, which can be used to adjust and control the tension during the material collection process, and to stably collect the dried rolled material.

[0020] The visual recognition and waste labeling unit is configured in the downstream process of the solution coating unit and includes a visual recognition component and a waste labeling component.

[0021] Furthermore, the visual recognition component includes a line scan camera element, which can meet the dynamic and accurate recognition of material defects at speeds of 0-200 mm / s. The line scan camera element can be combined with an encoder to achieve one-to-one comparison and recording of material position information and defect information. The waste marking component includes a color-coded marker element and a marker recognition element. The marker element can use the color-coded marking line at the corresponding position of the material defect as a waste identification signal. The marker recognition element can identify the marking line and send a signal to the controller indicating whether a marking line exists at the defect position, so that the controller can re-mark the defect.

[0022] In some embodiments, it also includes:

[0023] The first clamping unit is located at the rear end of the first tension maintaining unit and the front end of the solution coating unit, and includes an upper pressure roller assembly, a lower pressure roller assembly, and a control assembly.

[0024] Furthermore, the long plate consists of multiple thicker rolls of material bonded together on a plastic sheet, which is then conveyed to the solution coating unit at a specified speed by the first clamping unit, at which point the roll film main conveyor roller assembly stops operating.

[0025] Another aspect of the present invention provides a roll-to-roll drying method for coated sheets, the main steps of which are:

[0026] When the material is a flexible roll material, the roll material is unwound under the drive of the first feeding unit and the second feeding unit, and the material is subjected to tension buffering by the first tension maintaining unit.

[0027] Under the traction of the active traction mechanism or clamping mechanism, it reaches the lower end of the solution coating unit;

[0028] When the material is a thick or difficult-to-bend rolled material, such as a long plate, the long plate is subjected to tension buffering by the first tension maintaining unit, and then enters the first clamping unit. The material is automatically clamped and fed by the upper and lower rollers at a uniform speed to the lower end of the solution coating unit.

[0029] After the solution coating unit completes the solution coating, the rolled material is pulled to the lower end of the visual recognition and defect marking unit to complete the visual recognition and defect marking of the rolled material.

[0030] After being thoroughly dried in the drying unit, the rolled material enters the third feeding unit.

[0031] The third feeding unit performs tension buffering through the first tension maintaining unit, and then performs tension buffering through the second tension maintaining unit before completing the active winding of the rolled material.

[0032] When the material is a relatively hard long plate, the first clamping unit and the first tension maintaining unit simultaneously drive the long plate to move forward at a constant speed, reaching the lower part of the solution coating unit, and completing the coating of a specific solution line through the solution coating process.

[0033] The material conveying elements in the drying unit drive the long plate through constant temperature, circulating air, and dehumidification drying treatment, so that the rolled long plate material is fully dried.

[0034] The third feeding unit and the second tension maintaining unit uniformly wind up the dried long plate material.

[0035] The main control unit determines the tension status of the first tension maintaining unit and the second tension maintaining unit. After receiving the corresponding sensor signal, it controls the movement speed of the corresponding first clamping unit and the third feeding unit to keep the long plate in a stable and uniform feeding state.

[0036] The beneficial effects of this invention are as follows: 1. Improved equipment operational stability: Through precise adjustment of the second and first positions, and the design of the film-spraying assembly and film-spraying platform mechanism, the stability of the material during operation is ensured, avoiding equipment failures caused by positional deviations. 2. Smooth, tear-free unwinding and winding: Through the design of the first tension maintaining unit and the main film conveyor roller assembly in the unwinding module, and the first tension maintaining unit in the third feeding unit, the tension of the material is effectively controlled, avoiding tearing and material damage during unwinding and winding. 3. Improved drying effect: The coordinated work of the first temperature control component, air circulation supply component, drying component, second temperature control component, humidity control component, wind speed control component, and overall control component in the drying unit achieves precise control of the temperature and humidity inside the chamber, reducing energy consumption of the drying unit and improving drying efficiency and quality. 4. Increased production efficiency: Through the integrated design of the roll-to-roll coating drying device, a continuous automated production process from unwinding to drying to rewinding is realized, reducing manual intervention and improving production efficiency. 5. Improved Defect Identification Accuracy: The design of the visual recognition waste marking unit enables high-speed, dynamic, and accurate identification of material defects, improving product quality control. 6. Enhanced Equipment Adaptability: The visual recognition waste marking unit and first clamping unit on the equipment body allow it to adapt to different types and specifications of materials, exhibiting strong adaptability and flexibility. Attached Figure Description

[0037] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0038] Figure 1 This is a schematic diagram of the structure of a roll-to-roll coating drying device according to the present invention;

[0039] Figure 2 This is a schematic diagram of the structure of the first feeding unit, the solution coating unit, and the visual recognition waste labeling unit of the present invention;

[0040] Figure 3 This is a schematic diagram of the structure of the main conveyor roller assembly for film winding of the present invention;

[0041] Figure 4 This is a schematic diagram of the structure of the first tension maintaining unit of the present invention;

[0042] Figure 5 This is a schematic diagram of the structure of the main conveyor roller assembly for film winding of the present invention;

[0043] Figure 6This is a schematic diagram of the structure of the biological solution coating unit of the present invention;

[0044] Figure 7 This is a schematic diagram of the structure of the visual recognition waste labeling unit of the present invention;

[0045] Figure 8 This is a schematic diagram of the drying unit of the present invention;

[0046] Figure 9 This is a schematic diagram of the structure of the third feeding unit of the present invention;

[0047] Figure 10 This is a flowchart of the roll-to-roll drying method of the present invention. Detailed Implementation

[0048] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0049] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0050] Furthermore, the term "and / or" in the text includes three solutions. Taking A and / or B as an example, it includes technical solution A, technical solution B, and technical solution that simultaneously satisfies both A and B. In addition, the technical solutions of various embodiments can be combined with each other, but this must be based on the ability of a person skilled in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0051] Example 1

[0052] like Figure 1 - Figure 9 As shown, this application provides a technical solution: a roll-to-roll coating and drying device, including a drying unit 12 30, a first feeding unit 11, a first tension maintaining unit 12, a second feeding unit 10, a solution coating unit 20, a main control unit, a first clamping unit 13, a second tension maintaining unit 43, a third feeding unit 40, and a visual recognition waste labeling unit 60.

[0053] In this embodiment, the first feeding unit 11 is placed at the front end of the equipment and is used for the active unwinding of the roll material. After the first feeding unit 11 unwinds the material, it first collects the protective film onto the protective film collection mechanism 14. After the product film passes through the first tension maintaining unit 12 to adjust the tension, it reaches the second feeding unit 10, thus completing the uniform supply of material. When the roll material does not have a protective film, the protective film collection structure can stop working.

[0054] Specifically, such as Figure 3 As shown, the first feeding unit 11 includes a reducer 111 and a material preparation reel 112. The reducer 111 is connected to the material preparation reel 112 through a coupling. The unwinding speed can be adjusted according to the feedback signal of the first tension maintaining unit 12. The diameter of the material preparation reel 112 is not less than the diameter of the rolled material, which can prevent the material from flashing.

[0055] Specifically, such as Figure 4 As shown, the first tension maintaining unit 12 includes an adjustable gravity swing arm 121, a connecting shaft 122, and a swing roller 123. The left end of the first tension maintaining unit is connected to the swing roller 123, and the right end is connected to the adjustable gravity swing arm 121. The adjustable gravity swing arm 121 is provided with an adjustable gravity counterweight 1211 and a locking block 1212. The adjustable gravity counterweight 1211 can move within the connecting shaft 122, which has a dovetail groove. After being locked by the locking block 1212, it serves as the gravity source for tension balance. The adjustable gravity counterweight 1211 can be adapted to different material types when its position is different. The swing roller 123 can swing back and forth within a specific range during its up and down movement, and the swing roller 123 can swing back and forth within a specific range.

[0056] Specifically, such as Figure 5 As shown, the first clamping unit 13 includes a reducer 131, a drive roller 132, and an encoder 133. The reducer 131 is connected to the drive roller 132 via a coupling. The drive shaft of the reducer 131 is equipped with gears, which can be connected to the encoder 133 via a synchronous belt. Driven by the reducer 131, the drive roller 132 propels the material passing through it forward through friction. The friction between the drive roller 132 and the equipment body 50 serves as a pulling force, which can buffer the pulling force by the first tension maintaining unit 12 while preventing the material from slipping.

[0057] In this embodiment, as Figure 6As shown, the solution coating unit 20 includes a coating head 21, a first position adjustment module 22, and a second position adjustment module 23. The coating head 21 can be precisely positioned by the first position adjustment module 22 and the second position adjustment module 23. After the solution coating unit 20 is placed after the first feeding unit 10, it can uniformly transport the biological solution to the continuously moving roll material through the solution pipeline and coat at least one hydrophilic material. The coating solution can be in the form of lines, large-area wetting, or whole-area wetting. The second position adjustment module 23 is located on the equipment body 50 and can realize the adjustment of the solution coating unit 20 in the Z-direction position. The first position adjustment module 22 is located above the second position adjustment module 23 and is used to adjust the Y-direction displacement of the coating head 21. The first position adjustment module 22 includes a coarse adjustment scale module 221 and a fine adjustment screw head 222. The second position adjustment module 23 includes a coarse adjustment module 231 and a fine adjustment screw head 232. The coating head is located on the first position adjustment module 22 and can realize automatic solution cleaning and non-contact material spraying.

[0058] Specifically, the coating head 21 includes an air nozzle 211 and a solution spray head 212, which are arranged side by side on the first position adjustment module 22 for gold spraying and film application, respectively. The air nozzle 211 has a self-cleaning structure 2111, which avoids the need to disassemble the air nozzle for internal cleaning when changing the gold solution. The self-cleaning structure 2111 on the upper part of the air nozzle 211 can directly atomize the cleaning solution to achieve high-pressure cleaning inside the air nozzle 211. The solution spray head 212 has a vertically arranged steel needle 2121 at the bottom. The steel needle can avoid the bending of the traditional solution tube. The steel needle 2121 is also easy to clean and can achieve non-contact film application.

[0059] In this embodiment, as Figure 7 As shown, the equipment body 50 is also equipped with a visual recognition waste labeling unit 60, which is located on the right side of the solution coating unit 20 and before the drying unit 30. The visual recognition waste labeling unit 60 includes a visual recognition module 61 and a waste labeling module 62. The visual recognition module 61 is located in front of the waste labeling module 62 and can transmit the recognition signal to the waste labeling module 62. When the biological solution is coated on the surface of the hydrophilic membrane in the form of lines, the visual recognition module 61 will detect the shape of the lines according to the set parameters, and the waste labeling module 62 can identify defects and label them as waste.

[0060] Specifically, the visual recognition module 61 includes a line scan camera 611, which can meet the dynamic and accurate recognition of material defects at speeds of 0-200 mm / s. The line scan camera 611 is located on the upper part of the roll material travel track and can be combined with the encoder 133 to realize the one-to-one comparison and recording of material position information and defect information.

[0061] Specifically, the waste marking module 62 includes a color-coded marker 621 and a marker recognition device 622. The marker 621 is located between the line scan camera 611 and the marker recognition device 622, and can mark the corresponding defect location on the material with a color-coded marking line as a waste identification signal. The marker recognition device 622 can identify the color-coded marking line and provide feedback on whether the defect location is marked with a marking line.

[0062] In this embodiment, the drying unit 30 is located to the right of the standard waste module 60 and to the left of the third feeding unit 40, and can be used for rapid drying of rolled materials after they are wrapped.

[0063] Specifically, such as Figure 8 As shown, the drying unit 30 also includes a wind speed control component 31, an internal and external pressure difference sensing element 32, a heating element 33, a temperature and humidity sensing element 34, an exhaust element 35, a circulating air element 36, a wind speed sensing element, an air circulation supply component, and a second temperature control component 39. The drying unit 30 is divided into a mixing zone, an airflow heating zone, and a drying zone by an internal partition. The rotation speed of the wind speed control component 31 is related to the internal and external pressure difference sensing element 32 to maintain a set positive pressure value inside the chamber. The power of the heating element 33 is related to the temperature and humidity sensing element to maintain the hot air temperature at a set temperature value, and the air intake is adjusted according to the value of the temperature and humidity sensing element 34. When damp material enters the drying unit 30, the humidity of the airflow increases. At this time, the exhaust volume of the exhaust element 35 is related to the humidity detection value to maintain the humidity of the hot air inside the chamber at a set value. The circulating air baffle 37 is placed between the heating element 33 and the circulating air element 36 to dry the material. Hot air inside unit 30 can flow back to the circulating air baffle through the upper cavity, thereby re-contacting the heating element 33 to achieve hot air circulation heating and circulation. A baffle 38 is set at the air outlet of the circulating air element 36 to prevent direct contact between the circulating air and the material. The wind speed sensor is placed in the drying zone and can provide feedback on the wind speed value based on the material's moisture content and drying effect. The controller controls the ventilation volume of the wind speed control component 31 and the circulating air element 36. A second temperature control component 39 is set flush with the material to be dried to improve the drying effect. The air circulation supply component includes bottom air outlets and air outlets on the surface of the hollow roller. Hot air can be dispersed into the drying zone through the air circulation supply component. The air circulation supply component also includes a circulating fan, which can realize convenient adjustment of the hot air in the oven. The output air volume of the circulating air element can be adjusted according to the feedback value of the internal and external pressure difference sensor or the wind speed sensor to meet the circulation requirements of the heated hot air.

[0064] Furthermore, this equipment can be used for drying rolled materials in motion and drying sheet materials, simply by adding a corresponding material pulling mechanism and platform moving mechanism.

[0065] Furthermore, the second temperature control component 39 is a PTC electric heater. The controller achieves heating and temperature control of the airflow passing through the second temperature control component by controlling its temperature value and energizing frequency.

[0066] Furthermore, the exhaust components include electronic valves that automatically adjust the size of the exhaust opening based on data output from the humidity sensor to control the exhaust volume.

[0067] Furthermore, the exhaust components include manual valves, which automatically adjust the fresh air intake and recirculation components based on the humidity sensor output data to increase the internal and external pressure difference, thereby increasing the exhaust volume and controlling the humidity level.

[0068] Furthermore, the drying zone is equipped with upper and lower rotating shafts for the vertical winding of the roll material to achieve drying. The last rotating shaft before the roll material output drying unit 30 is also equipped with a torque motor to drive it, which can transmit and eliminate the friction force generated by the roll material on the shaft in the drying zone, and pull the roll material out of the drying oven with low tension.

[0069] In this embodiment, as Figure 9 As shown, the third feeding unit 40 is located at the tail end of the equipment and is used for the roll-up collection of dried roll materials.

[0070] Specifically, the third feeding unit 40 includes a winding mechanism 41 and a correction mechanism 42. The winding mechanism includes a reducer 411 and a take-up reel 412. The reducer 411 is fixed on the bracket and connected to the take-up reel 412 through a coupling. The rolled material is first corrected by the correction mechanism 42, and then the tension is adjusted by the second tension maintaining unit 43 before being wound up by the winding mechanism 41. The reducer 411 can adjust the unwinding speed according to the feedback signal from the second tension maintaining unit 43. The diameter of the take-up reel 412 is not less than the diameter of the rolled material to prevent the material from leaving the track. The correction mechanism 42 includes a locking knob 421, a Y-axis adjusting block 422, and a retaining nut 423. The locking knob 421 can slide back and forth in the chute to lock. The Y-axis adjusting block 422 can move the correction mechanism 42 as a whole along the Y-axis to correct the position of the rolled material. The retaining nut 423 can fasten the correction mechanism 42 to prevent it from moving back and forth.

[0071] Specifically, the second tension maintaining unit 43 includes an adjustable gravity swing arm 431, a connecting shaft 432, and a swing roller 433. The right end of the second tension maintaining unit 43 is connected to the swing roller 433, and the left end is connected to the adjustable gravity swing arm 431. The adjustable gravity swing arm 431 is provided with an adjustable gravity counterweight 4311 and a locking block 4312. The adjustable gravity counterweight 4311 can move within the connecting shaft 432, which has a dovetail groove. After being locked by the locking block 1212, it serves as the gravity source for tension balance. The adjustable gravity counterweight 4311 can be adapted to different material types when its position is different. The swing roller 433 is captured by the sensor 434 during its up-and-down movement. The swing roller 433 can swing back and forth within a specific range.

[0072] In this embodiment, the first clamping unit 70 is located at the rear end of the first tension maintaining unit and the front end of the film coating module, which can realize the clamping and conveying of long plate materials. The long plate is a variety of thicker rolls of material attached to a plastic plate, which is conveyed to the solution coating module by the first clamping unit 70 at a specified speed. When a long plate material enters its clamping conveying roller, the roll film main conveying roller assembly 70 in the device stops operating.

[0073] Specifically, the first clamping unit 70 includes an upper pressure roller 71, a lower pressure roller 72, and a control device 73. When the material is a long plate, the control device 73 controls the upper pressure roller 70 and the lower pressure roller 72 to squeeze each other, providing a stable feeding friction force for the long plate.

[0074] The roll-to-roll coating and drying device of this embodiment can adjust the tension of the rolled material by setting a first tension maintaining unit. At the same time, the adjustable gravity counterweight can adapt to the tension of different types of materials. Then, the rolled material is coated with solution as required. The coating head can be self-cleaned. Then the material enters the drying unit for drying. In the drying unit, it is effectively dried by circulating stable hot air and the second temperature control component. The dried rolled material finally enters the third feeding unit. After the tension is adjusted by the first tension maintaining unit and the deviation is corrected by the deviation correction mechanism, the winding operation is completed. This equipment can reduce manual production processes, improve the efficiency of automated production, and realize the automated production of rolled materials.

[0075] Example 2

[0076] This application also provides a technical solution: a modified embodiment of a roll-to-roll coating drying device, comprising: a conveyor belt conveying structure, which differs from a roll-type clamping and feeding structure, enabling uniform material transport and, compared to a clamping structure, better protecting the NC film material and preventing damage.

[0077] Example 3

[0078] This application also provides embodiments of a roll-to-roll drying method: such as Figure 10As shown, a roll-to-roll drying method includes the following steps:

[0079] Step S100: Start the equipment. The first feeding unit 10 starts working. The roll film main conveyor roller assembly 11 releases the roll material at a uniform speed to the roll film main conveyor roller assembly 13. If there is a protective film, the protective film collection mechanism 14 starts working to realize simultaneous unwinding and protective film collection.

[0080] Step S200: Under the traction of the roll film main conveyor roller assembly 13, the rolled material reaches the lower end of the solution coating unit 20 and is coated with the detection solution by the solution coating unit 20.

[0081] Step S201: After the rolled material reaches the designated position, the second position adjustment module 23 works, the coarse adjustment module 231 controls the wrapping head 21 to descend, and at the same time adjusts the fine adjustment spiral head 232 according to the thickness and width of the rolled material to achieve the required wrapping height.

[0082] Step S202: After the rolled material reaches the specified height, the first position adjustment module 22 adjusts the solution coating head 21 to the approximate position through the coarse adjustment scale module 221, and then the coating head 21 completes the Y-axis adjustment through the fine adjustment spiral head 222.

[0083] Step S300: After the solution coating unit 20 completes the solution coating, the roll material is pulled to the visual recognition and waste marking unit 60 to complete the visual recognition, location marking, defect marking and waste marking verification of the roll material;

[0084] Step S301: The rolled material after being coated with the detection solution can be detected by the visual identification waste labeling unit 60 to identify the solution line. Once the solution line is interrupted or aggregated, the visual identification waste labeling unit 60 judges it as an abnormal coating.

[0085] Step S302: The abnormal signal will be transmitted to the waste marking module 62, and the waste marking module 62 will mark the corresponding defect location with a marking line through the marker 621;

[0086] Step S303: The marking recognition device 622 can identify whether the marking line exists, compare the defect location and then send a signal back to determine whether the marking line has been accurately marked.

[0087] Step S400: The rolled material marked with a coating enters the drying unit 30 and is thoroughly dried within the drying unit 30;

[0088] Step S401: After the material enters the drying unit 30, the air speed control component 31 supplies fresh air at a constant speed. For example, the speed of the air speed control component 31 is set to 1000 rpm and the air volume is 500 m³ / min. 3 / h;

[0089] Step S402: Fresh air is heated by heating element 33 to become stable hot air. For example, the heating temperature is set to 50°C;

[0090] Step S403: The bottom circulating air element 36 delivers hot air to the material drying area;

[0091] Step S404: The temperature and humidity sensor element 34 of the drying zone monitors the temperature and humidity in real time. When the humidity is lower than the warning value, the top exhaust element 35 is turned off. Hot air enters the buffer zone through the top of the drying zone. The differential pressure gauge 32 of the buffer zone controls the action of the lever. After the hot air passes through the buffer zone and mixes with the hot air in the heating zone, it re-enters the drying zone.

[0092] Step S405: When the humidity is higher than the warning value, the top exhaust element 35 opens to exhaust the humidity. At this time, the wind speed control component 31 and the circulating air element 36 increase their power to increase the air supply until the humidity drops below the warning value.

[0093] Step S406: During the hot air circulation process, the moisture exhaust element 35 in the buffer zone is turned off, and the hot air from the drying zone is introduced into the buffer zone to mix and heat with the hot air from the heating zone before re-entering the drying zone to achieve hot air circulation.

[0094] Step S500: The dried roll material enters the third feeding unit 40;

[0095] Step S600: After the roll material is corrected by the correction structure 42 and the tension is adjusted by the first tension maintaining unit 43, it is stably and evenly wound on the winding mechanism 41.

[0096] Repeat the above steps until the rolled material completes the functions of unwinding, wrapping, identification, labeling, verification, drying, and rewinding.

[0097] The roll-to-roll coating and drying method of this embodiment enables automatic continuous unwinding of roll materials, sample solution coating, film scribing defect identification, defect marking and verification, automatic drying, and stable and neat winding. It also achieves efficient self-cleaning after the film scribing and gold spraying process, reducing manual intervention. Furthermore, the use of a high-efficiency, energy-saving, circulating, and dehumidifying drying unit avoids the waiting time caused by manual timed drying in the unit, ultimately achieving the winding of finished roll materials. This method can meet the requirements of rapid production of different batches of products.

[0098] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention's specification and drawings under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A roll-to-roll coating drying device, characterized in that, include: The equipment body is capable of solution coating and unwinding / rewinding of rolled materials; The drying unit includes a first temperature control component, an air circulation supply component, a drying component, a humidity control component, an air speed control component, and a main control component. As a processing unit after the rolled material is wrapped, the drying unit can achieve constant temperature, air speed, and humidity control for the rolled material. The air circulation supply component includes bottom air outlets and air outlets on the surface of the hollow roller, and hot air can be dispersed and sent into the drying area through the air circulation supply component.

2. The roll-to-roll coating drying apparatus as described in claim 1, characterized in that, The first temperature control component can adjust the output power of the heating element based on the feedback value of the temperature sensing element, thereby adjusting the temperature inside the oven in real time. The air circulation supply component can adjust the output air volume of the circulation air element according to the feedback value of the internal and external pressure difference sensing element or the wind speed sensing element to meet the circulation requirements of the heated air. The material conveying element within the drying unit ensures that the rolled material is dried at a uniform speed. The second temperature control component is located inside the drying component and can provide continuous radiant heat to the rolled material; The humidity control component can adjust the air volume at the exhaust component based on the feedback value of the humidity sensor, and work with the air circulation supply component to expel the moisture in the drying component. The wind speed control unit can provide real-time feedback to the main control unit based on the wind speed value inside the drying unit, and adjust the wind speed supplied by the air circulation supply unit according to the characteristics of the material to be dried. The main control unit can control the first temperature control unit, the air circulation supply unit, the drying unit, the second temperature control unit, and the humidity control unit based on the real-time detection values ​​of each sensor element.

3. The roll-to-roll coating drying apparatus as described in claim 1, characterized in that, Also includes: The first feeding unit, which serves as a roll material unloading unit, can actively unload roll flexible materials, and the unloading speed can be adjusted as needed. The first tension maintaining unit is provided with at least one adjustable gravity swing arm component and one feedback component, which can adjust the feeding speed through the swing arm position alarm. The second feeding unit, located after the first tension maintaining unit, can achieve stable and uniform feeding of flexible materials through a wrapping mode; A solution coating unit is located to the right of the first tension maintaining unit. The solution coating unit includes a coating head component containing an air nozzle element and a solution injection nozzle element. A main control unit is connected to a first feeding unit, a first tension maintaining unit, a second feeding unit, and a solution coating unit, and is used to control the operation of the first feeding unit, the first tension maintaining unit, the second feeding unit, and the solution coating unit. The first tension maintaining unit, when used for tension adjustment of the NC membrane without a backing, is further provided with a sliding component and a swing arm limiting component. The sliding component is used for tension adjustment of the NC membrane without a backing, and the swing arm limiting component can be a sensor or an encoder.

4. The roll-to-roll coating drying apparatus as described in claim 3, characterized in that, The solution coating unit further includes a first position adjustment component and a second position adjustment component. The coating head component can be precisely positioned by the first position adjustment component and the second position adjustment component, and can coat at least one hydrophilic material. The first position adjustment component includes a first coarse adjustment scale element and a first fine adjustment screw head element; The second position adjustment component includes a second coarse adjustment element and a second fine adjustment screw head element; The coating head component is located on the first position adjustment component and includes a self-cleaning air nozzle element and a non-contact spray head element; The self-cleaning air nozzle element has a self-cleaning module, which can realize convenient and automatic cleaning of the inside of the air nozzle; The bottom of the non-contact spray head element is equipped with a vertically adjustable steel needle, which enables non-contact spraying of materials.

5. The roll-to-roll coating drying apparatus as described in claim 3, characterized in that, Also includes: The first clamping unit is located at the rear end of the first tension maintaining unit and the front end of the solution coating unit, and includes an upper pressure roller assembly, a lower pressure roller assembly and a control assembly. The long plate consists of multiple thicker rolls of material bonded together on a plastic sheet. It is then conveyed to the solution coating unit at a specified speed by the first clamping unit, at which point the roll film main conveyor roller assembly stops operating.

6. The roll-to-roll coating drying apparatus as described in claim 4 or 5, characterized in that, Also includes: The second tension maintaining unit is located after the solution coating unit and is symmetrically arranged with the first tension maintaining unit. The third feeding unit is located at the tail end of the equipment. Its front end is equipped with a second tension maintaining unit, which can be used to adjust and control the tension during the material collection process, and to stably collect the dried rolled material.

7. The roll-to-roll coating drying apparatus as described in claim 6, characterized in that, Also includes: A visual identification and waste labeling unit is configured in the downstream process of the solution coating unit, and includes a visual identification component and a waste labeling component; The visual recognition component includes a line scan camera element, which can meet the dynamic and accurate recognition of material defects at speeds of 0-200 mm / s. The line scan camera element can be combined with an encoder to achieve one-to-one comparison and recording of material position information and defect information. The waste labeling component includes a color-coded marker element and a label recognition element. The marker element can use the color-coded marking line corresponding to the location of the material defect as a waste identification signal. The marker recognizer can identify the marking lines and send a signal to the controller indicating whether there are marking lines at the defect location, so that the controller can remark the defect.

8. A roll-to-roll drying method, applied to any one of the roll-to-roll drying apparatuses described in 1 to 7, characterized in that, include: When the material is a flexible roll material, the roll material is unwound under the drive of the first feeding unit and the second feeding unit, and the material is subjected to tension buffering by the first tension maintaining unit. Under the traction of the active traction mechanism or clamping mechanism, it reaches the lower end of the solution coating unit; When the material is a thick or difficult-to-bend rolled material, such as a long plate, the long plate is subjected to tension buffering by the first tension maintaining unit, and then enters the first clamping unit. The material is automatically clamped and fed by the upper and lower rollers at a uniform speed to the lower end of the solution coating unit. After the solution coating unit completes the solution coating, the rolled material is pulled to the lower end of the visual recognition and defect marking unit to complete the visual recognition and defect marking of the rolled material. After being thoroughly dried in the drying unit, the rolled material enters the third feeding unit. The third feeding unit performs tension buffering through the first tension maintaining unit, and then performs tension buffering through the second tension maintaining unit before completing the active winding of the rolled material.

9. The roll-to-roll coating drying method as described in claim 8, characterized in that, Also includes: The first clamping unit and the first tension maintaining unit simultaneously drive the long plate to move forward at a constant speed, reaching the lower part of the solution coating unit, and completing the coating of a specific solution line through the solution coating process. The material conveying elements in the drying unit drive the long plate through constant temperature, circulating air, and dehumidification drying treatment, so that the rolled long plate material is fully dried. The third feeding unit and the second tension maintaining unit uniformly wind up the dried long plate material. The main control unit determines the tension status of the first tension maintaining unit and the second tension maintaining unit, and controls the movement speed of the corresponding first clamping unit and the third feeding unit after receiving the corresponding sensor signal.

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