Batch Coating Apparatus with Controlled Immersion for Uniform Films
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Solution Overview
Problem
Existing batch coating processes for medical instruments, such as implantable blood glucose monitors, face challenges in achieving uniformity and consistency of the coating film due to various parameters affecting the thickness, opacity, and color of the film-forming layer on sensor electrodes.
Innovation Solution
A batch coating apparatus comprising a fixing mechanism, liquid holding mechanism, and liquid injection mechanism, controlled by a control device, to ensure precise immersion and withdrawal of work-pieces in coating liquid, maintaining uniform depth and angle for consistent film formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a pulling coating apparatus is used to dip sensor electrodes into sol and pull them out to form coating films, then the coating process can be performed, but the uniformity of the coating film thickness, opacity and color varies due to large number of variables affecting the coating process
Solution Approach 1:
The coating apparatus is divided into multiple independent liquid tanks, each containing a specific coating liquid. This segmentation allows independent control of each coating liquid's properties and application, reducing the complexity of managing multiple variables across a single large coating system.
Solution Approach 2:
The patent controls and adjusts parameters such as immersion depth, withdrawal speed, and coating liquid composition in each tank to optimize the coating process. By systematically varying these parameters across different tanks and time points, the apparatus achieves uniform coating films despite the complexity of multiple variables.
2Adaptability or versatility
If multiple variables are present in the coating process, then the coating process can be flexible, but the thickness, opacity and color of the film-forming layer show large differences
Solution Approach 1:
The apparatus prepares multiple coating liquids with predetermined compositions and properties before the coating process begins. Each liquid tank is pre-configured with specific coating liquid parameters, allowing the coating process to proceed systematically without real-time adjustments, thereby maintaining consistency while preserving flexibility.
Solution Approach 2:
The control device monitors and adjusts coating process parameters based on feedback from the coating liquid consumption and film formation characteristics. This feedback mechanism allows the system to maintain consistent film properties across multiple variables by making real-time corrections to immersion depth, withdrawal speed, and coating liquid flow.
3Ease of manufacture
If manual coating methods are used, then the process can be simple, but it is difficult to ensure uniformity of the coating film in batch production
Solution Approach 1:
The coating apparatus is designed to automatically control the immersion and withdrawal of sensor electrodes through programmed movements. The system self-regulates coating liquid distribution, immersion depth, and withdrawal speed without manual intervention, achieving uniform coating films while maintaining operational simplicity through automation.
Solution Approach 2:
The patent replaces manual mechanical coating operations with an automated control system that precisely manages the dipping and withdrawing processes. The control device uses programmed coordinates and speeds to replace manual skill, ensuring consistent coating film uniformity across batch production while keeping the overall process simple and straightforward.
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
The apparatus enhances the uniformity and consistency of the coating process, reducing variations in film thickness and improving the biocompatibility of medical instruments by ensuring uniform coating films on sensor electrodes.
Implementation Method 1
with the rapid evaporation of a solvent in the sol, a uniform thin film is formed on the surface of the sensor electrode infiltrated by the sol
Data Source
AI summary
Some embodiments of the disclosure describe a batch coating apparatus. In some examples, the batch coating apparatus includes a fixing mechanism, a liquid holding mechanism, a liquid injection mechanism and a control device. The fixing mechanism includes a plurality of fixing portions for fixing work-pieces to be coated. The liquid holding mechanism includes a plurality of liquid tanks arranged side by side. The liquid injection mechanism includes a liquid storage portion and an infusion portion. The control device is configured to control at least one of a relative movement between the fixing mechanism and the liquid holding mechanism and a relative movement between the liquid holding mechanism and the liquid injection mechanism. The control device is configured to control the liquid injection mechanism to supply the coating liquid via the infusion portion.