Air-mix injection device and film deposition system

Abstract

This system allows for reliable and easy film deposition on the target object, even for those unfamiliar with using this type of equipment, without contaminating the air in the deposition workspace. [Solution] A spraying device 3 that can be used in a film-forming system that sprays a mixture of powder and gas of a film-forming material onto a film-forming target X to deposit the powder on the surface of the film-forming target X, comprises a spraying unit 21 with a spraying port H21 for spraying the mixture, and an intake unit 22 with an intake port H22 for drawing in gas near the spraying device 3, wherein the spraying unit 21 and the intake unit 22 are arranged such that the spraying port H21 is located in the center of the intake port H22, and the device is configured so that powder that is sprayed from the spraying port H21 as a mixture and does not deposit on the film-forming target X can be drawn in from the intake port H22 together with the gas near the spraying device 3.

Description

Technical Field

[0001] The present invention relates to a mixture injection device that can be used in a film forming system that forms a film by spraying a mixture of powder of a film forming material and gas onto a film forming target to deposit the powder on the surface of the film forming target, and to a film forming system including such a mixture injection device. Background Art

[0002] A powder jet deposition method (hereinafter also referred to as "PJD method") is known, which forms a film by spraying fine powder onto an object at high speed to accumulate the powder on the surface of the object. It is known that film formation by this PJD method can be used, for example, in the dental field (aesthetic dentistry treatment field) when forming a film on the surface of a tooth by spraying fine particles as a film forming material onto the tooth for purposes such as filling a cavity, sealing exposed dentinal tubules, and improving the color tone of a discolored tooth.

[0003] For example, the following patent document discloses an invention of a film forming apparatus (treatment system) that can be used in the dental field. This treatment system includes a handpiece, a gas supply unit, and a powder supply unit, and is configured to be capable of forming a film by injecting powder toward a patient's tooth to cause the powder to adhere to the tooth. The handpiece is configured to be grippable by an operator (user), and is configured to be capable of injecting powder together with a gas such as air or nitrogen from an ejection port formed at the tip end. The gas supply unit is configured to be capable of supplying gas to the handpiece and the powder supply unit. Furthermore, the powder supply unit includes a classification device for classifying powder, and the classification device is configured to be capable of classifying powder while dispersing it in the gas supplied from the gas supply unit and supplying the classified powder to the handpiece.

[0004] Furthermore, this treatment system employs a configuration in which a gas channel and a powder channel are provided in the handpiece, and a mixture of gas supplied from a gas supply unit to the gas channel and powder supplied from a powder supply unit to the powder channel is ejected at high speed from the nozzle. Therefore, with this treatment system, by gripping the handpiece and pointing the nozzle at the teeth of the person being treated, the powder ejected from the nozzle along with the gas collides with the surface of the teeth and adheres to them, forming a film on the tooth surface. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2024-88401 (pages 3-8, figures 1-9) [Overview of the project] [Problems that the invention aims to solve]

[0006] However, the treatment system and its handpiece disclosed in the above-mentioned patent document have the following problems that need to be solved.

[0007] Specifically, the treatment system disclosed in the above-mentioned patent document employs a configuration in which a mixture of powder of the film-forming material and air is blown onto the object to be film-formed (in the invention of the above-mentioned patent document, a tooth) to adhere the powder to the surface of the object. In this case, when film formation is performed by the PJD method, some of the powder sprayed from the spraying device (handpiece) toward the object to be film-formed does not adhere to the object, but is repelled by the object or scattered by the flow of the sprayed gas without touching the object. For this reason, when performing film formation work using the treatment system disclosed in the above-mentioned patent document and its handpiece, there is a risk that the air in the work area may be contaminated by the presence of powder that did not adhere to the object to be film-formed.

[0008] In this case, for example, in the dental field, when cutting teeth with an air grinder, it is common practice to spray cold water along with air onto the treatment area for the purpose of cooling the cutting area and removing cutting debris. In this case, by placing the intake nozzle (intake port) of the intake device together with the air grinder near the treatment area, the cold water and cutting debris sprayed onto the treatment area are sucked up along with the surrounding air and removed from the mouth. By using such an intake device in combination with the above treatment system, it may be possible to avoid scattering (contamination of the air in the work area) into the surroundings by sucking up powder that was sprayed from the spray device and did not adhere to the target of film formation (tooth) along with the surrounding air.

[0009] However, when using the treatment system and the suction device together, if one person is performing the film deposition procedure, it is necessary to hold the handpiece of the treatment system with one hand and the suction nozzle of the suction device with the other hand, while keeping the nozzle opening of the handpiece and the suction port of the suction nozzle close together during the procedure. Therefore, when working alone, it is difficult to perform auxiliary tasks such as holding down the lips to expose the treatment area (tooth), and for those unfamiliar with this type of device, the film deposition procedure may be difficult.

[0010] On the other hand, when using the treatment system and the suction device together, having two people work—one to hold the handpiece of the treatment system and another to hold the suction nozzle of the suction device—makes it easier to perform the auxiliary tasks described above. However, since two workers are required to perform the film deposition, it becomes difficult to reduce the work cost. Furthermore, whether the work is performed by one person or two people, it is extremely difficult to maintain a constant distance between the nozzle of the handpiece and the suction port of the suction nozzle. As a result, the suction port may be far enough away from the nozzle that it becomes difficult to properly suction powder that did not adhere to the film deposition target through the suction port.

[0011] Although the above-mentioned patent document describes the problems that arise when used in the dental field, these problems are not limited to use in the dental field; similar problems occur when film deposition is performed using the PJD method in other fields as well.

[0012] This invention has been made in view of the problems that need to be solved, and its main objective is to provide a mixed gas injection device and a film deposition system that can reliably and easily deposit a film onto a target object without polluting the air in the work area, even for those unfamiliar with using this type of device. [Means for solving the problem]

[0013] To achieve the above objective, the gas mixture injection device described in claim 1 is a gas mixture injection device usable in a film-forming system that sprays a mixture of powder and gas of a film-forming material onto a film-forming object to deposit the powder onto the surface of the object, comprising: an injection unit with an injection port for injecting the gas mixture; and an intake unit with an intake port for drawing in gas near the gas mixture injection device, wherein the injection unit and the intake unit are arranged such that the injection port is located in the center of the intake port, and the powder that is injected as the gas mixture from the injection port and does not deposit on the film-forming object can be drawn in from the intake port together with the gas near the gas mixture injection device.

[0014] The air-fuel mixture injection device according to claim 2 is the air-fuel mixture injection device according to claim 1, wherein the intake portion is provided such that the rim of the intake port is located on the front side in the direction of injection of the air-fuel mixture relative to the rim of the injection port.

[0015] The air-fuel mixture injection device according to claim 3 is the air-fuel mixture injection device according to claim 1, wherein the injection unit is provided such that the rim of the injection port is located on the front side in the direction of injection of the air-fuel mixture relative to the rim of the intake port.

[0016] The air-fuel mixture injection device according to claim 4 is the air-fuel mixture injection device according to claim 1, wherein the intake portion has an inner diameter that gradually decreases near the rim of the intake port.

[0017] The air-fuel mixture injection device according to claim 5 is the air-fuel mixture injection device according to claim 1, wherein the intake portion is configured to be elastically deformable at least near the rim of the intake port.

[0018] The air-fuel mixture injection device according to claim 6 is the air-fuel mixture injection device according to claim 1, wherein the intake portion is formed of a translucent material at least near the edge of the intake port.

[0019] The film-forming system according to claim 7 comprises a mixed gas injection device according to any one of claims 1 to 6, a mixed gas supply device having a powder supply device for supplying the powder, a gas supply device for supplying gas, and a mixing device for mixing the powder and gas, and a purification device having an intake device for drawing in gas and a separation device for separating the powder contained in the gas, and is configured to perform film formation on the target for film formation.

[0020] The film deposition system according to claim 8 is the film deposition system according to claim 7, further comprising: a detection unit capable of detecting the distance between the nozzle and the object to be deposited on; and a control device that controls the air-mix supply device according to the detection result by the detection unit, wherein the control device starts supplying the air-mix from the air-mix supply device to the air-mix injection device when it is detected that the nozzle has approached the object to be deposited on by a distance less than a predetermined first distance, and stops supplying the air-mix from the air-mix supply device when it is detected that the nozzle has moved away from the object to be deposited by a distance greater than a predetermined second distance. [Effects of the Invention]

[0021] The mixed gas injection device according to claim 1 is configured for use in a film-forming system that sprays a mixed gas of powder and gas of a film-forming material onto a film-forming target to deposit the powder on the surface of the target. The injection unit and intake unit are provided such that the injection port for injecting the mixed gas is located in the center of the intake port for drawing in gas near the mixed gas injection device, and the device is configured to allow powder that is injected as a mixed gas from the injection port and does not deposit on the film-forming target to be sucked in from the intake port together with the gas near the mixed gas injection device. Furthermore, the film-forming system according to claim 7 comprises the above-mentioned mixed gas injection device, a mixed gas supply device having a powder supply device for supplying powder, a gas supply device for supplying gas, and a mixing device for mixing powder and gas, and a purification device having an intake device for drawing in gas and a separation device for separating powder contained in the gas, and is configured to perform film formation on a film-forming target.

[0022] Therefore, according to the mixed gas injection device described in claim 1 and the film deposition system described in claim 7, when performing film deposition work on a film deposition target, it is not necessary to separately bring the injection port of the mixed gas injection device for blowing the mixed gas and the intake port of the intake nozzle for sucking in surrounding air etc. closer to the film deposition location. Instead, by bringing only the mixed gas injection device close to the film deposition location and injecting the mixed gas from the injection port, it is possible to deposit powder contained in the mixed gas onto the film deposition target and to suck up powder that did not adhere to the film deposition target from the intake port. For this reason, even a person unfamiliar with using this type of device can reliably and easily deposit a film onto the film deposition target at low cost. Furthermore, because the injection port is located in the center of the intake port, powder that does not adhere to the film deposition target after being injected from the injection port can be suitably sucked up from the intake port, thus suitably avoiding the situation in which the air in the work area is contaminated by powder that did not adhere to the film deposition target. Furthermore, since the injection unit and intake unit are integrated to form a mixed gas injection device, fluctuations in the distance between the injection port and the intake port due to the operator's hand tremors during film formation are avoided. As a result, powder that does not adhere to the film target can be reliably sucked up from the intake port, thereby reliably preventing the scattering of powder that does not adhere to the film target.

[0023] In the air-fuel mixture injection device according to claim 2, the air intake portion is provided such that the rim of the air intake port is located on the near side in the injection direction of the air-fuel mixture with respect to the rim of the injection port. Therefore, according to the air-fuel mixture injection device according to claim 2 and a film forming system including such an air-fuel mixture injection device, when the air-fuel mixture is injected from the injection port toward a film formation target, in a state where the tip end of the injection portion (the rim of the injection port) is sufficiently close to the film formation target, a necessary and sufficient gap can be formed between the tip end of the air intake portion (the rim of the air intake port) and the film formation target. Accordingly, not only the gas injected as the air-fuel mixture from the injection portion (the injection port) but also the air around the tip end of the air intake portion (the rim of the air intake port) can be suitably sucked through the air intake port, so that the situation where powder that has not adhered to the film formation target scatters around the air-fuel mixture injection device can be suitably avoided.

[0024] In the air-fuel mixture injection device according to claim 3, the injection portion is provided such that the rim of the injection port is located on the near side in the injection direction of the air-fuel mixture with respect to the rim of the air intake port. Therefore, according to the air-fuel mixture injection device according to claim 3 and a film forming system including such an air-fuel mixture injection device, when the air-fuel mixture is injected from the injection port toward a film formation target, in a state where the tip end of the air intake portion (the rim of the air intake port) is brought into contact with the film formation target, the tip end of the injection portion (the rim of the injection port) can be made sufficiently close to the film formation target, and the air-fuel mixture can be injected from the injection port in this state. Accordingly, the situation where powder injected from the injection port that has not adhered to the film formation target scatters to the outside of the air intake portion can be suitably avoided.

[0025] In the air-fuel mixture injection device according to claim 4, the inner diameter of the air intake portion is gradually reduced in the vicinity of the rim of the air intake port. Therefore, according to the air-fuel mixture injection device according to claim 4 and a film forming system including such an air-fuel mixture injection device, while air can be sucked into the air intake portion from a wide range around the air-fuel mixture injection device (the injection portion), the flow velocity of intake air gradually increases in the air intake portion, so that the occurrence of clogging by powder or the like contained in the intake air on the deep side of the air intake portion can be suitably avoided.

[0026] In the air-fuel mixture injection device according to claim 5, at least the vicinity of the rim of the intake port in the intake portion is configured to be elastically deformable. Therefore, according to the air-fuel mixture injection device according to claim 5 and a film forming system including such an air-fuel mixture injection device, even if the tip end portion of the intake portion (the rim of the intake port) hits the film formation target during the film forming operation, as a result of deformation of the portion formed of an elastically deformable material, it is possible to suitably avoid situations where the film formation target is scratched or the air-fuel mixture injection device is damaged.

[0027] In the air-fuel mixture injection device according to claim 6, at least the vicinity of the rim of the intake port in the intake portion is formed of a light-transmissive material. Therefore, according to the air-fuel mixture injection device according to claim 6 and a film forming system including such an air-fuel mixture injection device, the air-fuel mixture spraying position on the film formation target and the formation degree of the film can be visually checked through the portion formed of the light-transmissive material, so that the occurrence of film formation defects can be suitably avoided.

[0028] The film forming system according to claim 8 comprises: a detection unit capable of detecting a distance between an injection port and a film formation target; and a control device that controls an air-fuel mixture supply device according to a detection result obtained by the detection unit, wherein the control device causes the air-fuel mixture supply device to start supplying air-fuel mixture to the air-fuel mixture injection device when it is detected that the injection port has approached the film formation target to a distance less than a predefined first distance, and causes the air-fuel mixture supply device to stop supplying air-fuel mixture when it is detected that the injection port has moved away from the film formation target to a distance exceeding a predefined second distance.

[0029] Therefore, the film deposition system described in claim 8 can suitably avoid the situation in which the mixed gas is sprayed from the nozzle at a position far from the object to be deposited, causing the surrounding air to be contaminated with powder. Furthermore, unlike configurations in which the start / stop of the spraying of the mixed gas is instructed by manual operation, the spraying of the mixed gas from the nozzle can be started / stopped simply by moving the mixed gas spraying device closer to / away from the object to be deposited. As a result, even those unfamiliar with using this type of device can deposit a film on the object more reliably and easily. [Brief explanation of the drawing]

[0030] [Figure 1] This is a diagram showing the configuration of the film deposition system 1. [Figure 2] This is an external perspective view of the injection device 3 in the film deposition system 1. [Figure 3] This is a cross-sectional view of the injection device 3. [Figure 4] This is a cross-sectional view of the injection device 3A according to another embodiment. [Figure 5] This is a front view of the injection device 3B according to another embodiment. [Figure 6] This is a front view of the injection device 3C according to another embodiment. [Modes for carrying out the invention]

[0031] Embodiments of the "mixture injection device" and the "film deposition system" will be described below with reference to the attached drawings.

[0032] The film deposition system 1 shown in Figure 1 is configured to be suitably used as a dental treatment tool using the PJD method (an example of a film deposition method in which a mixture of powder and gas of the film deposition material is blown onto the target object to deposit the powder and deposit it on the surface of the target object) for purposes such as filling cavities, sealing exposed dentinal tubules, and improving the color of discolored teeth, as an example of the treatment system (film forming device) disclosed in the aforementioned patent document. In this film deposition system 1, the main body 2 and the spraying device 3 are interconnected via an air hose 4.

[0033] The main unit 2 is equipped with an air supply device 11, a pressure regulating device 12, a powder supply device 13, a mixing device 14, solenoid valves 15a, 15b, a powder recovery device 16, a filtration device 17, an air intake device 18, and a control device 19. The air supply device 11 is, for example, composed of an "air tank integrated air compressor" and compresses and discharges gas (for example, atmospheric air) according to the control of the control device 19. Alternatively, instead of an integrated tank device, a configuration can be adopted in which an air tank is connected to a "tankless compressor" and air is stored in this air tank. The pressure regulating device 12 adjusts the amount supplied per unit time from the main unit 2 to the injection device 3 by adjusting the pressure of the gas supplied by the air supply device 11 according to the control of the control device 19. In this example of the film deposition system 1 (main unit 2), the air supply device 11 and the pressure regulating device 12 together constitute the "air supply device".

[0034] The powder supply device 13 is a "powder feeder," which is an example of a "powder supply device," and divides the "film-forming material powder" according to the control of the control device 19, and supplies a specified amount of powder to the mixing device 14. The mixing device 14 is composed of an "ejector," which is an example of a "mixing device," and mixes the gas and powder by dispersing the powder supplied from the powder supply device 13 into the gas discharged from the air supply device 11 and whose pressure is adjusted by the pressure adjustment device 12, and discharges the mixture of "film-forming material powder and gas." In this example of the film-forming system 1 (main body 2), the above components 11 to 14, 15a work together to constitute a "mixed gas supply device." Furthermore, in the actual film deposition system 1 (main body 2), a moisture removal device (not shown), such as a drain filter, is installed between the air supply device 11 and the mixing device 14 in the gas flow path supplied by the air supply device 11 (for example, between the air tank and the pressure regulating device 12). However, in order to facilitate understanding of the film deposition system 1 (main body 2), the illustration and explanation of this moisture removal device are omitted.

[0035] Solenoid valve 15a is opened and closed by the control device 19 to allow / regulate the supply of the air-fuel mixture discharged from the mixing device 14 to the injection device 3. Solenoid valve 15b is opened and closed by the control device 19 to allow / regulate the intake of air from the injection device 3 to the intake device 18. In this example, the film deposition system 1 (main body 2) employs "piezoelectric valves" which are solenoid valves that can open and close their valve bodies using a piezoelectric element, thereby enabling quick and reliable transitions from the closed state to the open state and from the open state to the closed state.

[0036] The powder recovery device 16 is an example of a "separation device" and is configured to separate and recover powder contained in the gas sucked in via the injection device 3, as will be described later. In this case, in the film formation system 1 (main body 2) of this example, the powder recovery device 16 is configured as a "cyclone separator" as an example. The filtration device 17 is a so-called "bag filter" and filters the powder (residue) that moves toward the intake device 18 without being separated from the gas in the powder recovery device 16, thereby allowing clean gas free of powder to be sucked into the intake device 18. In the film formation system 1 (main body 2) of this example, the powder recovery device 16 and the filtration device 17 together constitute a "purification device". The intake device 18 is configured as an "intake pump," which is an example of an "intake device," and sucks in gas according to the control of the control device 19.

[0037] The control device 19 comprehensively controls the main unit 2. Specifically, the control device 19 controls the air supply device 11 to pressurize and supply gas, controls the pressure adjustment device 12 to adjust the pressure of the gas supplied to the injection device 3, and controls the solenoid valve 15a to allow / restrict the supply of gas to the injection device 3. In this case, as will be described later, the control device 19 determines the distance between the injection device 3 and the film-forming target X based on the detection signal S24 of the distance sensor 24 installed in the injection device 3, and when it determines that the distance has approached below a predetermined "first distance", it allows the supply of the gas mixture from the main unit 2 to the injection device 3, and when it determines that the distance has moved beyond a predetermined "second distance", it restricts (stops) the supply of the gas mixture from the main unit 2 to the injection device 3. Furthermore, the control device 19 controls the intake device 18 to draw in gas and controls the solenoid valve 15b to allow / restrict the intake of gas from the injection device 3 to the main unit 2.

[0038] The injection device 3 is an example of a "mixture injection device," in which an injection section 21, an intake section 22, and a gripping section 23 are integrally formed, and a distance sensor 24 is provided. The injection section 21 is an example of an "injection section," and as shown in Figure 1, it is connected to the solenoid valve 15a of the main body 2 via an air hose 4, and as shown in Figures 2 and 3, an injection port H21 is opened so that the mixture pressurized from the main body 2 can be injected toward the film-forming target X, etc. The intake section 22 is an example of an "intake section," and as shown in Figure 1, it is connected to the solenoid valve 15b of the main body 2 via an air hose 4, and as shown in Figures 2 and 3, an intake port H22 is opened so that gas (air) in the vicinity of the injection device 3 (specifically, in the vicinity of the injection port H21 of the injection section 21) can be drawn in.

[0039] In this case, the injection device 3 of this example is configured such that the injection port H21 is located in the center of the intake port H22, and the injection unit 21 and intake unit 22 are provided, and as will be described later, the powder that is injected as a mixture from the injection port H21 and does not accumulate on the film-forming target X can be sucked in from the intake port H22 together with the gas (air) near the injection device 3. Furthermore, in the injection device 3 of this example, the intake unit 22 is provided such that the tip 22a of the intake unit 22 (i.e., the rim of the intake port H22) is located on the near side (right side in the figure) in the direction of injection of the mixture from the injection device 3 (direction of arrows A1 and A2 shown in Figure 3) relative to the tip 21a of the injection unit 21 (i.e., the rim of the injection port H21).

[0040] Furthermore, in the injection device 3 of this example, the inner diameter of the intake section 22 near the tip 22a (near the rim of the intake port H22) is gradually reduced along the direction of gas intake (the direction of arrows B1 and B2 shown in Figure 3). In addition, in the injection device 3 of this example, the tip 22a portion of the intake section 22 (near the rim of the intake port H22) is made of a light-transmitting and elastically deformable material. Specifically, as an example, the tip 22a portion of the intake section 22 is molded from a translucent silicone resin or the like.

[0041] The gripping portion 23 has an air supply passage L21 that communicates with the spraying portion 21 (spray port H21) and an intake passage L22 that communicates with the intake portion 22 (intake port H22), and is sized so that a user can grip the spraying device 3 with one hand. In this example of the film deposition system 1 (spraying device 3), the gripping portion 23 is provided to enable work suitable for when a user grips the spraying device 3 to perform the film deposition work. However, when the "spraying device" is attached to a moving mechanism such as a robot arm to perform the film deposition work instead of this configuration, a fixing portion (not shown) that fixes the "spraying device" to the moving mechanism is provided in place of the gripping portion 23 of the spraying device 3.

[0042] The distance sensor 24 is an example of a "detection unit," and as an example, it is disposed in the intake unit 22 together with the injection unit 21 to detect the distance between the injection port H21 and the film deposition target X, etc., and outputs a detection signal S24 indicating the detection result. Note that the distance sensor 24 is not shown in Figure 3. In this case, the location of the distance sensor 24 (detection unit) is not limited to inside the intake unit 22, but can also be placed outside the intake unit 22 (not shown).

[0043] Next, the process of depositing a film onto the target X (patient's tooth) using the film deposition system 1 (injection device 3) will be explained with reference to the attached diagram.

[0044] In this film deposition system 1, when the start of the film deposition process is instructed by operating a switch on an operating unit (not shown) in the main body 2, the control device 19 controls the air supply device 11 to start compressing the gas (air). In this case, immediately after the start of the process, and before the injection device 3 is brought close to the film deposition target X as described later, the control device 19 has moved the solenoid valve 15a to the closed state, and no gas is supplied from the main body 2 to the injection device 3. As a result, the gas (air) compressed by the air supply device 11 is stored in an air tank (not shown). In this example of film deposition system 1 (main body 2), the air supply device 11 continues to compress the gas so that the pressure of the gas in the air tank exceeds a predetermined lower limit until the end of the film deposition process is instructed by operating a switch on the operating unit, and the air supply device 11 is stopped when the pressure in the air tank reaches a predetermined upper limit. The following explanation of matters concerning the storage of gas in the air tank in this air supply device 11 is omitted.

[0045] Furthermore, the control device 19 controls the powder supply device 13 to start the division of powder and supplying it to the mixing device 14. In addition, the control device 19 controls the intake device 18 to start intake and controls the solenoid valve 15b to open, thereby allowing intake from the injection device 3 (intake section 22) to the main body 2 (intake device 18).

[0046] In this case, air near the rim of the nozzle H21 is drawn in from the intake port H22 of the intake section 22 of the injection device 3. The drawn-in air is then drawn into the main body 2 via the intake passage L22 and air hose 4 within the gripping section 23, passes through the solenoid valve 15b, the powder recovery device 16, and the filtration device 17 in that order, and is then drawn into the intake device 18 before being released into the atmosphere from the exhaust port of the intake device 18. At this point, before the injection of the mixed gas from the injection section 21 has started, the air drawn in from the intake port H22 is exhausted from the exhaust port of the intake device 18 without the separation of powder in the powder recovery device 16 or the filtration of powder in the filtration device 17 taking place.

[0047] In this state, the gripping portion 23 of the spraying device 3 is gripped, and the tip portion 21a of the spraying portion 21 is brought closer to the film-forming target X. At this time, the control device 19, based on the detection signal S24 from the distance sensor 24, determines that the distance between the film-forming target X and the spraying device 3 (tip portion 21a of the spraying portion 21) has fallen below a predetermined "first distance (for example, 1.0 mm)" and the spraying device 3 has approached the film-forming target X, and then switches the solenoid valve 15a to the open state. As a result, the high-pressure air stored in the air tank is adjusted to a predetermined pressure when it passes through the pressure adjustment device 12, and the powder supplied from the powder supply device 13 is dispersed when it passes through the mixing device 14, becoming a "mixture of film-forming material powder and gas" which is supplied to the spraying device 3 via the solenoid valve 15a and air hose 4.

[0048] Furthermore, the mixed gas supplied to the injection device 3 is passed through the air supply passage L21 as indicated by arrow A1 in Figure 3, and is injected from the injection port H21 of the injection unit 21 toward the film-forming target X as indicated by arrow A2. As a result, the powder injected as a mixed gas from the injection port H21 comes into contact with the surface of the film-forming target X, causing the powder to accumulate on the surface of the film-forming target X and forming a film.

[0049] In this case, as described above, in the spray device 3 of this example, the tip portion 22a of the intake portion 22 (near the rim of the intake port H22) is made of a light-transmitting material. Therefore, it is possible to visually confirm the area on the film-forming target X where the mixed gas is sprayed (in this example, the teeth on which the film should be formed) and the degree of film formation by passing through the portion made of the light-transmitting material. Furthermore, as described above, in the spray device 3 of this example, the tip portion 22a of the intake portion 22 (near the rim of the intake port H22) is made of an elastically deformable material. Therefore, even if the tip portion 22a of the intake portion 22 comes into contact with the film-forming target X during the film formation process, the portion made of the elastically deformable material will deform, effectively preventing damage to the film-forming target X or damage to the spray device 3.

[0050] In this example, when forming a film using the PJD method with the film formation system 1 (injector 3), some of the powder ejected from the nozzle H21 does not accumulate on the film target X, but is repelled by the film target X or scattered without touching the film target X by riding on the flow of gas ejected with the powder from the nozzle H21. In this case, the film formation system 1 (injector 3) in this example draws in gas (air) near the injection device 3 (specifically, near the nozzle H21 in the injection section 21) from the intake port H22 into the intake section 22. Therefore, the powder that is repelled by the film target X or tries to scatter without touching the film target X by riding on the flow of gas ejected with the powder from the nozzle H21 is drawn into the intake section 22 along with the air around the injection device 3 (near the nozzle H21), as shown by arrow B1 in Figure 3. As a result, scattering of powder into the surroundings is avoided, and the film formation work can be continued without contaminating the air in the work area.

[0051] In this case, as described above, the injection device 3 in this example is provided such that the rim (tip 22a) of the intake port H22 is located on the near side relative to the rim (tip 21a) of the injection port H21 in the direction of injection of the mixed gas (direction of arrows A1 and A2 shown in Figure 3). Therefore, the film deposition work can be performed with the tip 21a of the injection device 21 closer to the film deposition target X than the tip 22a of the intake device 22. This ensures that the mixed gas is reliably sprayed onto the film deposition site, and air is drawn into the intake device 22 not only from the air sprayed from the injection device 3 (injection device 21) but also from a wide area around the injection device 3 (injection device 21), making it possible to completely remove any powder that might scatter around the area where the mixed gas is sprayed.

[0052] Furthermore, in the injection device 3 of this example, as described above, the inner diameter of the intake section 22 near the tip 22a (near the rim of the intake port H22) is gradually reduced along the direction of gas intake (the direction of arrows B1 and B2 shown in Figure 3). Therefore, while air can be drawn into the intake section 22 from a wide area around the injection device 3 (injection section 21), the flow velocity of the intake air gradually increases within the intake section 22, which effectively prevents clogging of the intake air with powder or other particles in the intake air at the back of the intake section 22 (intake passage L22, etc.). In this case, by making the area near the rim of the intake port H22 in the intake section 22 a funnel shape as in this example, air can be effectively drawn in from a sufficiently wide area near the tip 21a of the injection section 21, and the intake resistance can be sufficiently reduced.

[0053] Meanwhile, the mixture of gas and powder drawn into the intake section 22 moves along the intake passage L22 as indicated by arrow B2 and is drawn into the main body 2 via the air hose 4. The mixture drawn into the main body 2 then passes through the solenoid valve 15b and flows into the powder recovery device 16, where most of the powder contained in the mixture is separated from the air. Any small amount of powder that is not separated from the air in the powder recovery device 16 is sufficiently collected by the filtration device 17. This reliably prevents the situation in which air containing powder is drawn into the intake device 18, and effectively avoids the failure of the intake device 18 or the contamination of the surrounding air by exhaust gas containing powder being discharged from the intake device 18.

[0054] After this, when it is determined that the film deposition on the target X is complete, the operator moves the tip 21a of the spray unit 21 away from the target X. At this time, the control device 19, based on the detection signal S24 from the distance sensor 24, determines that the distance between the target X and the spray device 3 (tip 21a of the spray unit 21) has fallen below a predetermined "second distance (for example, 2.0 mm)" and the spray device 3 has moved away from the target X, and then switches the solenoid valve 15a to the closed state. This stops the spraying of the mixed gas from the spray unit 21 (spraying of powder onto the target X). When the film deposition work is to be resumed, the tip 21a of the spray unit 21 is brought closer to the target X again, and the spraying of the mixed gas from the spray unit 21 (spraying of powder onto the target X) is started as described above. By performing this operation for all film deposition locations where a film should be formed, the film deposition on the target X is completed.

[0055] Thus, the spraying device 3 is configured to be usable in a film-forming system 1 that sprays a mixture of powder and gas of the film-forming material onto the film-forming target X to deposit the powder on the surface of the film-forming target X and form a film. The spraying section 21 and the intake section 22 are provided such that the spraying port H21 for spraying the mixture is located in the center of the intake port H22 that draws in gas near the spraying device 3. The device is configured so that powder that is sprayed as a mixture from the spraying port H21 and does not deposit on the film-forming target X can be sucked in from the intake port H22 along with the gas near the spraying device 3 (near the intake port H22). Furthermore, this film deposition system 1 is configured to perform film deposition on the target X, comprising the above-mentioned injection device 3, a powder supply device 13 for supplying powder, a gas supply device (gas supply device 11 and pressure regulating device 12) for supplying gas, a mixed gas supply device 14 for mixing powder and gas, and a purification device (gas recovery device 16 and filtration device 17) for drawing in gas and a powder recovery device 16 for separating powder contained in the gas.

[0056] Therefore, with this injection device 3 and film deposition system 1, when performing film deposition on the film deposition target X, there is no need to perform the complicated task of separately bringing the injection port of the "mixture injection device" for blowing the mixture and the intake port of the intake nozzle for drawing in ambient air closer to the film deposition location. By simply bringing the injection device 3 close to the film deposition location and injecting the mixture from the injection port H21, the powder contained in the mixture can be deposited onto the film deposition target X, and any powder that does not adhere to the film deposition target X can be sucked up from the intake port 22. For this reason, even those unfamiliar with using this type of device can reliably and easily perform film deposition on the film deposition target X at low cost. Furthermore, because the injection port H21 is located in the center of the intake port H22, any powder that does not adhere to the film deposition target X after being injected from the injection port H21 can be suitably sucked up from the intake port H22, thus suitably avoiding contamination of the work area air by powder that does not adhere to the film deposition target X. Furthermore, since the spraying unit 21 and the intake unit 22 are integrally provided to constitute the spraying device 3, fluctuations in the distance between the spraying port H21 and the intake port H22 due to the operator's hand tremors during the film formation process are avoided. As a result, powder that does not adhere to the film target X can be reliably sucked in from the intake port H22, thereby reliably preventing the scattering of powder that does not adhere to the film target X.

[0057] Furthermore, in this injection device 3, the intake section 22 is provided such that the rim of the intake port H22 is located on the near side in the direction of injection of the mixed gas relative to the rim of the injection port H21. Therefore, with this injection device 3 and film deposition system 1, when the mixed gas is injected from the injection port H21 onto the film deposition target X, a sufficient gap can be created between the tip 22a of the intake section 22 and the film deposition target X when the tip 21a of the injection section 21 is sufficiently close to the film deposition target X. As a result, not only the gas (air) injected as a mixed gas from the injection section 21 (injection port H21) but also the air surrounding the tip 22a of the intake section 22 can be suitably drawn in from the intake port H22, thus suitably preventing powder that did not adhere to the film deposition target X from scattering around the injection device 3.

[0058] Furthermore, in this injection device 3, the inner diameter of the intake section 22 is gradually reduced near the rim of the intake port H22. Therefore, with this injection device 3 and film formation system 1, air can be drawn into the intake section 22 from a wide area around the injection device 3 (injection section 21), and the flow velocity of the intake air gradually increases within the intake section 22, thereby effectively avoiding clogging of the intake section 22 (intake passage L22, etc.) by powders contained in the intake air.

[0059] Furthermore, in this injection device 3, at least the area near the rim of the intake port H22 in the intake section 22 is configured to be elastically deformable. Therefore, with this injection device 3 and film formation system 1, even if the tip 22a of the intake section 22 comes into contact with the film to be formed X during the film formation process, the part made of an elastically deformable material will deform, effectively preventing damage to the film to be formed X or damage to the injection device 3.

[0060] Furthermore, in this injection device 3, at least the area near the rim of the intake port H22 in the intake section 22 is formed of a light-transmitting material. Therefore, with this injection device 3 and film deposition system 1, the areas where the mixed gas is sprayed on the film deposition target X and the degree of film formation can be visually confirmed by passing through the parts formed of the light-transmitting material, thus effectively avoiding the occurrence of film deposition defects.

[0061] Furthermore, this film deposition system 1 includes a distance sensor 24 capable of detecting the distance between the nozzle H21 and the film deposition target X, and a control device 19 that controls the "mixture supply device" according to the detection result (detection signal S24) from the distance sensor 24. The control device 19 starts supplying the mixture from the "mixture supply device" to the injection device 3 when it detects that the nozzle H21 has approached the film deposition target X to a predetermined "first distance" or less, and stops supplying the mixture from the "mixture supply device" when it detects that the nozzle H21 has moved away from the film deposition target X to a predetermined "second distance" or more.

[0062] Therefore, this film deposition system 1 effectively avoids the situation where the mixed gas is sprayed from the nozzle H21 at a position far from the film deposition target X, causing the surrounding air to be contaminated with powder. Furthermore, unlike configurations where the start / stop of the mixed gas spraying is instructed by manual operation, the spraying of the mixed gas from the nozzle H21 can be started / stopped simply by moving the spraying device 3 closer to / away from the film deposition target X. As a result, even those unfamiliar with using this type of device can deposit a film on the film deposition target X more reliably and easily.

[0063] Next, other embodiments of the "mixture injection device" will be described with reference to the attached drawings. Note that components similar to those of the injection device 3 described above, and components other than the injection device 3 in the film deposition system 1, are denoted by the same reference numerals, and redundant explanations will be omitted.

[0064] The injection device 3A shown in Figure 4 is another example of a "mixture injection device," and is configured almost identically to the injection device 3, except that it is equipped with an intake section 22A instead of the intake section 22 in the aforementioned injection device 3. The intake section 22A in this injection device 3A is another example of an "intake section," and is configured to be connectable to the solenoid valve 15b of the main body 2 via an air hose 4, similar to the intake section 22 in the injection device 3, and the intake port H22A is opened to allow intake of gas (air) in the vicinity of the injection device 3A (specifically, in the vicinity of the injection port H21 in the injection section 21). Furthermore, in this injection device 3A, the injection section 21 and the intake section 22A are arranged such that the injection port H21 is located in the center of the intake port H22A, and the powder that was injected as a mixture from the injection port H21 and did not accumulate on the film-forming target X can be sucked in from the intake port H22A along with the gas (air) in the vicinity of the injection device 3A.

[0065] In this example, the injection device 3A is configured such that the tip 21a of the injection unit 21 (i.e., one rim of the injection port H2) is located on the near side (right side in the figure) of the tip 22Aa of the intake unit 22A (i.e., the rim of the intake port H22A) in the direction of injection of the gas mixture from the injection device 3A (direction of arrows A1 and A2). Furthermore, in the injection device 3A of this example, the inner diameter of the portion of the intake unit 22A on the tip 22Aa side (near the rim of the intake port H22A) is gradually reduced along the direction of gas intake (direction of arrows B1 and B2). In addition, in the injection device 3A of this example, the portion of the intake unit 22A on the tip 22Aa side (near the rim of the intake port H22A) is made of a light-transmitting and elastically deformable material. Specifically, as an example, the tip portion 22Aa of the intake section 22A is molded from a translucent silicone resin or the like.

[0066] In a film deposition operation using the film deposition system 1 equipped with such an injection device 3A, in the same manner as in the aforementioned film deposition operation using the film deposition system 1 equipped with the injection device 3, when the start of the film deposition process is instructed by operating a switch on an operation unit (not shown), the compression of gas (air) by the air supply device 11 (storage in the air tank), the division of powder by the powder supply device 13 and supply to the mixing device 14, and the intake of gas (air) by the intake device 18 are initiated.

[0067] In this state, the gripping portion 23 of the injection device 3A is gripped and the tip portion 22Aa of the intake portion 22Aa is brought into contact with the film-forming target X, so that the film-forming target area on the film-forming target X is covered by the intake portion 22A, as shown in Figure 4. At this time, the control device 19, based on the detection signal S24 from the distance sensor 24, determines that the distance between the film-forming target X and the injection device 3A (tip portion 22a of the injection portion 21) has fallen below a predetermined "first distance (for example, 1.0 mm)" and that the injection device 3A (intake portion 22A) has come into contact with the film-forming target X, and then switches the solenoid valve 15a to the open state. As a result, the high-pressure air stored in the air tank is adjusted to a predetermined pressure when it passes through the pressure adjustment device 12, and the powder supplied from the powder supply device 13 is dispersed when it passes through the mixing device 14, becoming a "mixture of film-forming material powder and gas" which is then supplied to the injection device 3A via the solenoid valve 15a and the mixing device 14.

[0068] Furthermore, the air-fuel mixture supplied to the injection device 3A is passed through the air supply passage L21 as indicated by arrow A1 in Figure 4, and is injected from the injection port H21 of the injection unit 21 towards the film-forming target X within the intake unit 22 as indicated by arrow A2. As a result, the powder injected as air-fuel mixture from the injection port H21 accumulates on the surface of the film-forming target X, and a film is formed on the surface of the film-forming target X.

[0069] In this case, similar to the intake section 22 in the aforementioned injection device 3, the portion of the intake section 22A on the tip side 22Aa (near the rim of the intake port H22A) of the injection device 3A in this example is made of a light-transmitting material. Therefore, it is possible to visually confirm the area on the film-forming target X where the mixed gas is sprayed (in this example, the teeth on which the film should be formed) and the degree of film formation by passing through the portion made of the light-transmitting material. Furthermore, in the injection device 3A in this example, the portion of the intake section 22A on the tip side 22Aa (near the rim of the intake port H22A) is made of an elastically deformable material. Therefore, when the tip 22Aa of the intake section 22A is brought into contact with the film-forming target X during the film formation process, the portion made of the elastically deformable material deforms, which effectively prevents damage to the film-forming target X or damage to the injection device 3A.

[0070] Here, even when forming a film using the PJD method with the film formation system 1 equipped with the injection device 3A, some of the powder ejected from the nozzle H21 does not accumulate (adhere) to the film target X, but is repelled by the film target X or is scattered without touching the film target X by being carried by the flow of gas ejected together with the powder from the nozzle H21.

[0071] In this example, the spraying device 3A is configured such that, as described above, the tip 21a of the spraying section 21 is positioned on the near side (right side in the figure) of the spraying direction of the mixed gas from the spraying device 3A (direction of arrows A1 and A2) relative to the tip 22Aa of the intake section 22A. Therefore, by pressing the tip 22Aa of the intake section 22A against the film-forming target X as described above, and spraying the mixed gas from the nozzle H21 while the spraying area of ​​the film-forming target X is covered by the intake section 22A, powder that would be repelled by the film-forming target X or would attempt to scatter without touching the film-forming target X by riding on the flow of gas sprayed together with the powder from the nozzle H21 moves within the intake section 22A as shown by arrow B1 in Figure 4. As a result, scattering of powder around the intake section 22A is avoided, and the film-forming work can be continued without contaminating the air in the work area.

[0072] Furthermore, in the injection device 3A of this example, the inner diameter of the intake section 22A near the tip 22Aa (near the rim of the intake port H22A) is gradually reduced along the direction of gas intake (the direction of arrows B1 and B2 shown in Figure 4). Therefore, by allowing air to be drawn into the intake section 22 from a wide area around the injection device 3A (injection section 21) and gradually increasing the flow velocity of the intake air, it is possible to suitably avoid clogging of the intake section 22A (intake passage L22, etc.) with powders contained in the intake air. In this case, by making the area near the rim of the intake port H22A of the intake section 22A a funnel shape as in this example, it is possible to suitably draw in air from a sufficiently wide area near the tip 21a of the injection section 21, and at the same time, the intake resistance can be sufficiently reduced.

[0073] Furthermore, regarding the flow of the air-mixed gas drawn in from the intake section 22A during the film deposition operation using the film deposition system 1 equipped with the injection device 3A, the same details as during the aforementioned film deposition operation using the film deposition system 1 equipped with the injection device 3 are omitted as they would otherwise be redundant. With this, the film deposition on the target X is completed.

[0074] Thus, in this injection device 3A, the injection unit 21 is positioned such that the rim of the injection port H21 is located on the near side in the direction of injection of the mixed gas relative to the rim of the intake port H22A. Therefore, with this injection device 3A and the "film formation system" equipped with the injection device 3A, when the mixed gas is injected from the injection port H21 onto the film formation target X, the tip 22Aa of the intake unit 22A is in contact with the film formation target X, and the tip 21a of the injection unit 21 is brought sufficiently close to the film formation target X, and the mixed gas is injected from the injection port H21 in that state. This effectively prevents powder that is injected from the injection port H21 and does not adhere to the film formation target X from scattering outside the intake unit 22.

[0075] The configurations of the "mixture injection device" and the "film deposition system" are not limited to the examples of the injection devices 3 and 3A described above, and the film deposition system 1 equipped with injection devices 3 and 3A. For example, injection device 3, in which the injection unit 21 and intake unit 22 are arranged such that one injection port H21 is located in the center of one intake port H22, and injection device 3A, in which the injection unit 21 and intake unit 22A are arranged such that one injection port H21 is located in the center of one intake port H22A, were described as examples, but the number of "injection ports H" and "intake ports H" is not limited to these examples of configurations.

[0076] Specifically, the injection device 3B shown in Figure 5 is yet another example of a "mixture injection device," in which the injection port H21B (another example of an "injection unit") and intake unit 22 are arranged such that multiple (in this example, three) injection ports H21B, H21B, H21B (another example of an "injection port") are located in the center of a single intake port H22. Note that in the injection device 3B shown in the same figure, and in the injection device 3C shown in Figure 6 which will be referenced later, components that have the same function as the injection devices 3 and 3A described above are denoted by the same reference numerals, and redundant explanations are omitted. Furthermore, the injection device 3C shown in Figure 6 is yet another example of a "mixture injection device," in which one injection port H21 and an intake section 22C (another example of an "intake section") are arranged such that one injection port H21 is located in the center of a plurality (in this example, three) intake ports H22C, H22C, H22C (another example of an "intake port") arranged in an annular shape in a front view. The same effects as those of the injection devices 3B, 3C and the film deposition system 1 equipped with injection devices 3B, 3C can be achieved.

[0077] Furthermore, while we have described a control example in which gas (air) from the vicinity of the "mixture injection device" is continuously drawn in from the "intake port" from immediately after the start of the film deposition process on the film deposition target X until the end of the series of operations, instead of this configuration, it is possible to start intake from the "intake port" immediately before the injection of the mixture from the "injection port" begins, or to stop intake from the "intake port" immediately after the injection of the mixture from the "injection port" stops. Specifically, for example, when the "air-mix injector" is brought closer to the "film-forming target" at a distance less than a predetermined "third distance (for example, 2.0 mm)" which is longer than the "first distance (1.0 mm in the above example)" as determined by the detection signal S24 from the distance sensor 24, intake from the "air intake port" can be started. Also, when the "air-mix injector" is moved further away from the "film-forming target" at a distance greater than a predetermined "fourth distance (for example, 3.0 mm)" which is longer than the "second distance (2.0 mm in the above example)" as determined by the detection signal S24 from the distance sensor 24, intake from the "air intake port" can be stopped.

[0078] Furthermore, although the explanation described an example in which injection start / stop and intake start / stop according to the distance specified by the detection result (detection signal S24) from the "detection unit (distance sensor 24)", it is also possible to adopt a configuration in which the timing of injection start / stop and intake start / stop can be manually instructed. In either configuration, by starting intake before injection starts and stopping intake after injection stops, it is possible to suitably avoid contamination of the work area air by powder that was not applied to the "film-forming target". In addition, although the example of using "air (atmosphere)" as the "gas" injected together with the powder as a "mixed gas" was described, "gases other than air (atmosphere)", such as nitrogen and various inert gases, can be used. When using these "gases", the "air supply device" can be configured by providing a "tank in which the gas is stored" instead of the air supply device 11 in the above-described film-forming system 1.

[0079] Furthermore, although the explanation has given examples of configurations suitably usable in the field of dental treatment, the fields of use of the "mixed gas injection device" and "film deposition system" are not limited to these, and the "mixed gas injection device" and "film deposition system" can be suitably used when depositing films on various targets other than "teeth". [Explanation of Symbols]

[0080] 1. Film deposition system 2 Main body 3,3A,3B,3C injection device 4 Air hoses 11. Air supply device 12 Pressure Regulator 13 Powder feeding device 14 Mixing device 15a, 15b Solenoid valves 16. Powder recovery device 17 Filtration device 18 Intake system 19 Control device 21,21B Injection part 21a, 21Aa, 22a Tip 22, 22A, 22C Intake section 23 Gripping part 24 Distance Sensors H21,H21B injection port H22, H22A, H22C air intake L21 Air line L22 Intake Line S24 Detection signal X Target for film deposition

Claims

1. A mixed gas injection device usable in a film deposition system that sprays a mixture of powder and gas of a film deposition material onto a target object to deposit a film, thereby depositing the powder onto the surface of the target object, An injection unit having an injection port for injecting the aforementioned mixture, The system comprises an intake section with an intake port for drawing in gas near the air-fuel mixture injection device, A mixture injection device is provided such that the injection port is located in the center of the intake port, and the injection unit and the intake unit are configured to allow the powder that is injected as a mixture from the injection port and does not accumulate on the film-forming target to be sucked in from the intake port together with gas near the mixture injection device.

2. The air intake section is provided such that the rim of the air intake port is located on the front side in the direction of injection of the air mixture relative to the rim of the injection port.

3. The air-mix injection device according to claim 1, wherein the injection unit is provided such that the rim of the injection port is located on the front side in the direction of injection of the air-mix in relation to the rim of the intake port.

4. The air intake portion has an inner diameter that gradually decreases near the rim of the air intake port, as described in claim 1.

5. The air intake portion is configured such that at least the vicinity of the rim of the air intake port is elastically deformable, as described in claim 1.

6. The air intake portion is formed of a translucent material at least near the rim of the air intake port, according to claim 1.

7. A mixture injection device according to any one of claims 1 to 6, A mixed gas supply device having a powder supply device for supplying the powder, a gas supply device for supplying gas, and a mixing device for mixing the powder and gas, The purification device comprises an intake device for drawing in gas and a separation device for separating the powder contained in the gas, A film deposition system configured to perform film deposition on the aforementioned target.

8. A detection unit capable of detecting the distance between the injection nozzle and the object to be film-formed, The system includes a control device that controls the mixed gas supply device according to the detection result from the detection unit, The film deposition system according to claim 7, wherein the control device detects that the nozzle has approached the object to be deposited by a predetermined first distance, the control device starts supplying the air-mixed mixture from the air-mixed mixture supply device to the air-mixed mixture injection device, and stops supplying the air-mixed mixture from the air-mixed mixture supply device when it detects that the nozzle has moved away from the object to be deposited by a predetermined second distance.

Images