Atmospheric Electromagnetic Coil for Vacuum Metal Vapor Coating
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Solution Overview
Problem
Existing dry coating apparatuses with electro-magnetic coils in vacuum environments face arcing issues, leading to complex structures, increased costs, and limited high-speed coating capabilities due to the need for insulation and feed-through components, which also result in overheating and vibration-related problems.
Innovation Solution
The electro-magnetic coil is positioned in the atmosphere, eliminating the risk of arcing and omitting related components, allowing for a simplified structure and enhanced metal vapor generation, with the coating process occurring in a vacuum chamber using a separation unit and insulation flange to maintain vacuum integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the electro-magnetic coil is disposed in a vacuum environment, then metal vapor generation capacity is improved, but arcing occurs between coil windings or between the coil and external conductors
Solution Approach 1:
The patent divides the system into two separate environments: the electro-magnetic coil operates in the atmosphere while the coating process occurs in a vacuum chamber. This segmentation allows each component to operate in its optimal environment without compromising the other, preventing arcing while maintaining metal vapor generation capacity
Solution Approach 2:
The patent introduces an intermediary structure (the vacuum chamber with its window or aperture) that separates the atmospheric coil environment from the vacuum coating environment. This intermediary allows the coil to generate metal vapor in the atmosphere while the vacuum chamber receives and utilizes the vapor for coating without exposing the coil to vacuum conditions
2Reliability
If insulation structures are added to prevent arcing, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent extracts the electro-magnetic coil from the vacuum environment and places it in the atmosphere, thereby eliminating the need for complex insulation structures and feed-through components that would be required to prevent arcing in a vacuum. This extraction removes the source of the arcing problem rather than adding complex protective measures
3Reliability
If feed-through components are used to apply high frequency current in vacuum, then reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts the high frequency power supply and electro-magnetic coil from the vacuum environment and places them in the atmosphere, eliminating the need for complex vacuum feed-through components. The high frequency current can now be applied directly to the coil without requiring specialized vacuum-compatible electrical connections
4Quantity of substance
If the electro-magnetic coil is disposed in vacuum, then metal vapor generation is improved, but overheating and vibration occur due to arcing and insulation limitations
Solution Approach 1:
The patent segments the system so that the electro-magnetic coil operates in the atmosphere where effective cooling and vibration management can be implemented, while the vacuum chamber separately maintains the coating process. This allows the coil to generate metal vapor without suffering from overheating and vibration issues that would occur in a vacuum environment
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration stabilizes the coating process, enables higher frequency currents, reduces power consumption, and increases productivity by allowing faster coating speeds while minimizing manufacturing costs and heat-related issues.
Implementation Method 1
a coating material is surrounded by an electro-magnetic coil, and a high frequency AC current generated by high frequency power is applied to the electro-magnetic coil. Here, the coating material is heated by the generated electro-magnetic fields
Implementation Method 2
A coating material, for example, metal vapor, may be coated on a surface of a steel strip through various well-known methods such as a deposition method in which a coating material is coated on a substrate, e.g., a continuous (high-speed) proceeding steel strip in a vacuum
Data Source
AI summary
Provided is a dry coating apparatus for coating a coating material, i.e., deposition vapor (metal vapor) on a substrate (a steel strip). The dry coating apparatus includes a coating part disposed in a vacuum to coat deposition vapor generated through heating and evaporation of a supplied coating material onto a proceeding object to be coated and a heating source disposed in an atmosphere to heat and levitate the coating material in the coating part.