Integrated automatic production device for preparing functional coating on surface of PC (Polycarbonate) film

Abstract

The utility model discloses an integrated automatic production device for preparing a functional coating on the surface of a PC (Polycarbonate) film, and relates to the technical field of high polymer material processing, a single screw extruder is used for processing a raw material into a PC film with uniform thickness; the conveyor belt mechanism is arranged in a subsequent process of the single-screw extruder; the plasma treatment surface cleaning and treatment system is used for carrying out surface cleaning and activating treatment on the PC film; the slit coating system is used for applying a functional coating with accurate thickness on the PC film; the scraper system is used for adjusting and optimizing the thickness and flatness of the functional coating; and the vacuum heating and drying system, the film surface optical detection system and the film rolling system are sequentially arranged in a subsequent process of the conveyor belt mechanism. Through the highly integrated design and the combination of the plasma processing technology, the full-automatic production process from raw materials to finished products is achieved, the production efficiency and the product quality are improved, and meanwhile the labor cost and the energy consumption are reduced.

Description

TECHNICAL FIELD

[0001] The utility model relates to high polymer material processing technical field, especially to the manufacturing and surface treatment technology of plastic film, more specifically to a kind of integrated automatic production device for PC film surface functional coating preparation. BACKGROUND

[0002] Polycarbonate (PC) film has been widely used in electronics, optics, medical and other fields due to its excellent mechanical properties, transparency and heat resistance. With the higher requirements of these application fields on the surface properties of PC film, such as wear resistance, anti-pollution and other functional coating applications, the traditional manufacturing process gradually shows its limitations.

[0003] Traditionally, the production process of PC film usually includes the following steps: first, using an extruder to prepare a base film, and then applying a functional coating through a coating process. However, the traditional production process has the following main problems:

[0004] Process dispersion: each processing step is relatively independent, lacking effective integration, leading to complex production process and difficult management. For example, from film making to coating and drying, each step needs to set up equipment and parameters separately, increasing operation complexity and floor space.

[0005] Poor coating uniformity: traditional coating methods are difficult to accurately control coating thickness, easily causing uneven coating, affecting product quality consistency.

[0006] Low automation: relying on a large number of manual operations, not only increases labor cost, but also easily introduces errors due to human factors. For example, in the coating process, manual adjustment of coating speed and thickness may cause uneven coating.

[0007] Insufficient quality monitoring: lack of effective real-time quality detection means, unable to timely discover and correct defects in the production process, resulting in low yield. Existing quality detection can only be carried out after batch ends, unable to realize online real-time monitoring.

[0008] Poor coating adhesion: due to insufficient cleanliness of substrate surface or low surface energy, leading to poor adhesion between coating and substrate, affecting the durability and functionality of coating. Untreated PC film surface has low surface energy, while ideal coating adhesion requires higher surface energy.

[0009] In recent years, plasma treatment has been widely used in materials science as an advanced surface cleaning and modification technology. This technology can effectively remove surface contaminants and increase surface energy without altering the physical properties of the substrate, thereby significantly enhancing the adhesion between the coating and the substrate. However, in practical industrial applications, there are few instances of integrating plasma treatment technology into continuous production lines; in most cases, it still needs to be performed separately or manually, limiting the maximization of its efficiency and effectiveness.

[0010] In view of the problems existing in the above-mentioned background technology, realizing an integrated automated production process from raw materials to finished products, and also utilizing plasma treatment technology to significantly improve coating adhesion, thereby solving a variety of problems existing in the prior art, is a problem that urgently needs to be solved by those skilled in the art. Utility Model Content

[0011] In view of this, the present invention provides an integrated automatic production device for preparing functional coatings on the surface of PC films, aiming to solve the above-mentioned technical problems.

[0012] To achieve the above objectives, the present invention adopts the following technical solution:

[0013] An integrated automated production apparatus for preparing functional coatings on PC film surfaces includes:

[0014] A single-screw extruder, wherein the single-screw extruder is used to process raw materials into PC films of uniform thickness;

[0015] A conveyor belt mechanism is located in the downstream process of the single-screw extruder and is used to transport the PC film;

[0016] A plasma surface cleaning and treatment system is provided at the front of the conveyor belt mechanism and is used to perform surface cleaning and activation treatment on the PC film.

[0017] A slot coating system, located in the middle of the conveyor belt mechanism, is used to apply a functional coating of precise thickness to the PC film.

[0018] A scraper system is provided at the rear of the conveyor belt mechanism and is used to adjust and optimize the thickness and smoothness of the functional coating.

[0019] The vacuum heating and drying system, the thin film surface optical inspection system, and the film winding system are sequentially arranged in the subsequent process of the conveyor belt mechanism.

[0020] Through the above technical solution, this utility model provides an integrated automatic production device for preparing functional coatings on PC films, which integrates a single-screw extrusion film system, a plasma treatment surface cleaning and treatment system, a slot coating system, a doctor blade system, a vacuum heating and drying system, a film surface optical inspection system, and a film winding system. It can not only realize an integrated automatic production process from raw materials to finished products, but also significantly improve coating adhesion by utilizing plasma treatment technology, thereby solving a number of problems existing in the prior art and bringing significant technological progress to the PC film manufacturing industry.

[0021] Preferably, the integrated automatic production device for preparing functional coatings on the surface of PC films further includes a central control system, which includes a computer and a power distribution box, and is used to coordinate the operating parameters of each subsystem.

[0022] Preferably, in the above-mentioned integrated automatic production device for preparing functional coatings on PC film surfaces, the plasma treatment surface cleaning and treatment system includes a vacuum box located at the front of the conveyor belt mechanism. The vacuum box has a vacuum pump interface and an argon gas interface, and an radio frequency power supply is installed on the vacuum box.

[0023] Preferably, in the above-mentioned integrated automatic production device for preparing functional coatings on PC film surfaces, the slot coating system controls the flow rate of the coating material by means of a horizontal flow pump.

[0024] Preferably, in the above-mentioned integrated automatic production device for preparing functional coatings on the surface of PC films, the doctor blade system can adjust the pressure and angle of the doctor blade.

[0025] Preferably, in the above-mentioned integrated automatic production device for preparing functional coatings on the surface of PC films, the vacuum heating and drying system includes a heating chamber equipped with a vacuum system.

[0026] Preferably, in the above-mentioned integrated automated production device for preparing functional coatings on PC film surfaces, the film surface optical inspection system includes a high-resolution camera and an image analysis system.

[0027] Preferably, in the above-mentioned integrated automatic production device for preparing functional coatings on the surface of PC films, the film winding system winds the film by a rotating roller driven by a motor.

[0028] As can be seen from the above technical solution, compared with the prior art, this utility model discloses an integrated automatic production device for preparing functional coatings on the surface of PC films, which has the following beneficial effects:

[0029] 1. High Integration and Automation: This invention integrates a single-screw extruder film production system, a plasma treatment surface cleaning and processing system, a slot coating system, a doctor blade system, a vacuum heating and drying system, a film surface optical inspection system, and a film winding system into a single automated production line through a highly integrated design. Compared to traditional, fragmented processes, this integrated design simplifies management processes, reduces floor space, and lowers equipment maintenance costs. Simultaneously, the entire production process is highly automated, reducing manual intervention and improving production efficiency and product consistency.

[0030] 2. Advanced Plasma Treatment Technology: Low-temperature plasma treatment technology is used to clean and activate the PC film surface, increasing surface energy and thus enhancing the adhesion between subsequent coatings and the substrate. Low-temperature plasma treatment effectively removes surface contaminants and increases surface energy without altering the physical properties of the substrate, significantly improving coating adhesion. Compared to traditional manual or step-by-step processing methods, this method is more efficient and yields better results.

[0031] 3. Precise control of coating thickness and quality monitoring: Traditional coating methods struggle to precisely control coating thickness, easily leading to uneven coating. This invention, through the combination of a slit coating system and a doctor blade system, can precisely control coating thickness and smoothness, ensuring uniform distribution of the coating across the entire film width.

[0032] 4. Real-time Quality Monitoring: Traditional quality inspections can only be performed after a batch is finished, making online real-time monitoring impossible and resulting in low yield rates. This invention, equipped with a high-resolution camera and image analysis software, provides a thin-film surface optical inspection system that can monitor the film surface in real time, automatically identify and mark any defects or flaws, and promptly detect and correct defects during production, ensuring flawless product output and improving yield rates.

[0033] 5. Energy-saving design and environmental performance: Traditional drying and curing processes are usually carried out under normal pressure, which consumes a lot of energy and is prone to quality problems. This utility model adopts a vacuum heating drying system, which accelerates the coating curing process in a vacuum environment, reduces the formation of bubbles and other factors that may cause uneven coating, and reduces energy consumption. This not only improves curing efficiency, but also reduces energy consumption and environmental pollution, which is in line with the concept of green manufacturing. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of this utility model 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 embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0035] Figure 1 The attached figure is a schematic diagram of the integrated automatic production device for preparing functional coatings on the surface of PC films provided by this utility model.

[0036] Figure 2 The attached figure is a structural schematic diagram of the single-screw extruder provided by this utility model;

[0037] Figure 3 The attached figure is a schematic diagram of the structure of the plasma treatment surface cleaning and treatment system provided by this utility model;

[0038] Figure 4 The attached figure is a structural schematic diagram of the slot coating system provided by this utility model;

[0039] Figure 5 The attached figure is a structural schematic diagram of the scraper system provided by this utility model;

[0040] Figure 6 The attached figure is a schematic diagram of the vacuum heating and drying system provided by this utility model;

[0041] Figure 7 The attached figure is a schematic diagram of the structure of the thin film surface optical inspection system provided by this utility model;

[0042] Figure 8 The attached figure is a schematic diagram of the structure of the film winding system provided by this utility model.

[0043] in:

[0044] 1-Single screw extruder;

[0045] 2- Conveyor belt mechanism;

[0046] 3- Plasma treatment surface cleaning and treatment system;

[0047] 31-Vacuum chamber; 311-Vacuum pump interface; 312-Argon gas interface; 32-RF power supply;

[0048] 4-Slot coating system;

[0049] 41-Horizontal flow pump;

[0050] 5-Scraper system;

[0051] 51-Scraper;

[0052] 6-Vacuum heating and drying system;

[0053] 61-Heating chamber; 62-Vacuum system;

[0054] 7-Thin film surface optical inspection system;

[0055] 71-High-resolution camera; 72-Image analysis system;

[0056] 8-Wrap film system;

[0057] 81-Roll;

[0058] 9-Central control system;

[0059] 91-Computer; 92-Distribution box. Detailed Implementation

[0060] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0061] See appendix Figure 1 This utility model discloses an integrated automated production device for preparing functional coatings on PC film surfaces, comprising:

[0062] Single-screw extruder 1 is used to process raw materials into PC films of uniform thickness.

[0063] Conveyor belt mechanism 2 is located in the downstream process of single screw extruder 1 and is used to transport PC film;

[0064] Plasma treatment surface cleaning and treatment system 3 is located at the front of conveyor belt mechanism 2 and is used to perform surface cleaning and activation treatment on PC film.

[0065] Slit coating system 4, located in the middle of conveyor belt mechanism 2, is used to apply a functional coating of precise thickness to PC film.

[0066] The scraper system 5 is located at the rear of the conveyor belt mechanism 2 and is used to adjust and optimize the thickness and smoothness of the functional coating.

[0067] The vacuum heating and drying system 6, the thin film surface optical inspection system 7, and the film winding system 8 are sequentially located in the subsequent process of the conveyor belt mechanism 2.

[0068] In this embodiment, the single-screw extruder 1 also includes a feeding device, a die, and a cooling device before and after it. The raw material enters the single-screw extruder 1 through the feeding device, melts under high temperature and high pressure, and is formed into a film through the die. Then, it is cooled and shaped by the cooling device to form a PC film of uniform thickness.

[0069] See appendix Figure 1 and attached Figure 2 It also includes a central control system 9, which includes a computer 91 and a power distribution box 92. The central control system 9 is used to coordinate the operating parameters of each subsystem.

[0070] See appendix Figure 3 The plasma surface cleaning and treatment system 3 includes a vacuum chamber 31 located at the front of the conveyor belt mechanism 2. The vacuum chamber 31 has a vacuum pump interface 311 and an argon gas interface 312, and an radio frequency power supply 32 is installed on the vacuum chamber 31. The plasma treatment system uses low-temperature plasma technology, which utilizes a plasma generator to generate plasma to clean and activate the thin film surface, improve the surface energy, and enhance the adhesion of subsequent coatings.

[0071] See appendix Figure 4 The slot coating system 4 controls the flow rate of the coating material via a horizontal flow pump 41. By precisely controlling the coating speed and amount, the slot coating system 4 ensures a uniform coating thickness. The system can adjust its parameters according to different coating process requirements, adapting to various coating materials and process specifications.

[0072] See appendix Figure 5 The scraper system 5 enables adjustment of the pressure and angle of the scraper 51. The scraper system 5 is equipped with adjustable pressure and angle, allowing for adjustment of coating thickness and smoothness as needed, further optimizing the coating effect. In this embodiment, the pressure and angle adjustment uses a conventional screw adjustment and shaft adjustment structure, which will not be described in detail here.

[0073] See appendix Figure 6 The vacuum heating and drying system 6 includes a heating chamber 61, which is equipped with a vacuum system 62. In this embodiment, the vacuum heating and drying system 6 is equipped with a temperature and humidity control module, which can accelerate the coating curing process in a vacuum environment and reduce bubble formation and other factors that may cause uneven coating.

[0074] See appendix Figure 7 The thin film surface optical inspection system 7 includes a high-resolution camera 71 and an image analysis system 72, which are used to automatically identify and mark any defects to ensure the output of flawless products.

[0075] See appendix Figure 8 The film winding system 8 winds the film using a rotating roll 81 driven by a motor. The film winding system 8 is responsible for neatly winding the coated PC film for easy storage and transportation. The system controls tension through motor speed control, ensuring film flatness and integrity.

[0076] In this embodiment, a single-screw extruder 1 processes the raw material into a PC film of uniform thickness. Next, a plasma surface cleaning and treatment system 3 cleans and activates the film surface to enhance the adhesion of subsequent coatings. A slot coating system 4 precisely controls the coating thickness, ensuring uniformity, while a doctor blade system 5 further optimizes the coating effect. A vacuum heating and drying system 6 accelerates the coating curing process, reducing energy consumption and the risk of material deformation. A film surface optical inspection system 7 monitors film quality in real time, ensuring the output of defect-free products. Finally, the treated PC film is neatly wound by a film winding system 8 for easy storage and transportation.

[0077] This invention, through a highly integrated design and combined with plasma processing technology, realizes a fully automated production process from raw materials to finished products, improving production efficiency and product quality while reducing labor costs and energy consumption.

[0078] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to the method section.

[0079] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An integrated automated production device for preparing functional coatings on PC film surfaces, characterized in that, include: A single-screw extruder (1) is used to process raw materials into PC films of uniform thickness; A conveyor belt mechanism (2) is provided in the downstream process of the single screw extruder (1) and is used to transport the PC film; Plasma treatment surface cleaning and treatment system (3), the plasma treatment surface cleaning and treatment system (3) is located at the front of the conveyor belt mechanism (2) and is used to perform surface cleaning and activation treatment on the PC film; A slit coating system (4) is located in the middle of the conveyor belt mechanism (2) and is used to apply a functional coating of precise thickness to the PC film. A scraper system (5) is provided at the rear of the conveyor belt mechanism (2) and is used to adjust and optimize the thickness and smoothness of the functional coating. The vacuum heating and drying system (6), the thin film surface optical inspection system (7), and the film winding system (8) are sequentially arranged in the subsequent process of the conveyor belt mechanism (2).

2. The integrated automatic production device for preparing functional coatings on PC film surfaces according to claim 1, characterized in that, It also includes a central control system (9), which includes a computer (91) and a power distribution box (92), and the central control system (9) is used to coordinate the operating parameters of each subsystem.

3. The integrated automatic production device for preparing functional coatings on PC film surfaces according to claim 1, characterized in that, The plasma treatment surface cleaning and treatment system (3) includes a vacuum chamber (31) located at the front of the conveyor belt mechanism (2). The vacuum chamber (31) has a vacuum pump interface (311) and an argon interface (312). A radio frequency power supply (32) is installed on the vacuum chamber (31).

4. The integrated automatic production device for preparing functional coatings on PC film surfaces according to claim 1, characterized in that, The slot coating system (4) controls the flow rate of the coating material by means of a horizontal flow pump (41).

5. The integrated automatic production device for preparing functional coatings on PC film surfaces according to claim 1, characterized in that, The scraper system (5) enables the adjustment of the pressure and angle of the scraper (51).

6. The integrated automatic production device for preparing functional coatings on PC film surfaces according to claim 1, characterized in that, The vacuum heating and drying system (6) includes a heating chamber (61) equipped with a vacuum system (62).

7. The integrated automatic production device for preparing functional coatings on PC film surfaces according to claim 1, characterized in that, The thin film surface optical inspection system (7) includes a high-resolution camera (71) and an image analysis system (72).

8. The integrated automatic production device for preparing functional coatings on PC film surfaces according to claim 1, characterized in that, The film winding system (8) winds the film by a rotating roll (81) driven by a motor.

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