Coating Apparatus Gap Adjustment via Pneumatic Actuation
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Solution Overview
Problem
Existing coating apparatuses face challenges in accurately adjusting the gap thickness for uniform coating due to limitations in precision adjustment methods, such as bolt and nut systems, which lead to backlash and damage, and temperature-based methods that are complex and slow.
Innovation Solution
A coating apparatus with an air pressure controller and gap adjusting mechanism using an air pressure cylinder, allowing for automatic or manual control of coating thickness by varying the size of the coating solution outlet through forward and backward movements of a moving member, ensuring uniform coating thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a bolt and nut system is used to adjust the gap, then the gap can be adjusted, but minute adjustments are difficult and backlash occurs during mode changes
Solution Approach 1:
The patent replaces the traditional mechanical bolt and nut system with a piezoelectric actuator system. The piezoelectric actuator converts electrical signals directly into precise mechanical displacement, enabling minute gap adjustments without the backlash and friction issues inherent in mechanical thread systems. This substitution allows for both high precision and ease of operation through electronic control.
Solution Approach 2:
The patent employs a pneumatic system with a pressure controller to drive the piezoelectric actuator. By controlling the air pressure supplied to the actuator, the system achieves precise gap adjustment. The pneumatic system provides smooth, frictionless actuation compared to mechanical systems, eliminating backlash and enabling continuous variable adjustment of the gap size.
2Adaptability or versatility
If the gap is continuously adjusted using a bolt and nut, then the gap can be modified, but damage occurs due to friction between the bolt and nut
Solution Approach 1:
The patent eliminates the mechanical contact between bolt and nut by using a piezoelectric actuator driven by pneumatic pressure. This non-contact or minimal-contact actuation method removes the friction that causes wear and damage, allowing continuous gap adjustment without compromising the durability of the adjustment mechanism.
3Manufacturing precision
If expansion and contraction of metal due to temperature changes is used to adjust the gap, then the gap can be adjusted, but the method is complicated and has low response speed
Solution Approach 1:
The patent replaces the slow thermal expansion method with a piezoelectric actuator that responds instantaneously to electrical signals. The piezoelectric material exhibits rapid strain response to applied voltage, enabling real-time gap adjustment with high response speed, unlike thermal methods that require time for heat transfer and temperature change.
Solution Approach 2:
The patent changes the physical parameter used for gap adjustment from temperature (thermal expansion) to electrical field (piezoelectric effect). By applying voltage to the piezoelectric actuator, the gap is adjusted through electrical parameter control, which provides much faster response compared to thermal parameter changes.
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
Enables precise and efficient adjustment of coating thickness, maintaining uniformity by controlling the rate of discharge of the coating solution, reducing damage and complexity, and improving response speed.
Implementation Method 1
a gap adjusting arrangement including a plurality of gap adjusting portions arranged on the first body portion to adjust a size of the coating solution outlet, the plurality of gap adjusting portions being arranged in a width direction of the base material
Implementation Method 2
The air pressure cylinder may also include a forward air pressure controller and a backward air pressure controller
Data Source
AI summary
A coating apparatus to apply a coating solution onto a base material, including a first body portion, a second body portion spaced-apart by a gap from the first body portion, a coating solution inlet arranged in one region of the second body portion, a coating solution passage connecting the coating solution inlet to said gap, a coating solution outlet arranged at one end of the gap to discharge the coating solution supplied to the coating solution inlet and a gap adjusting arrangement including a plurality of gap adjusting portions arranged on the first body portion to adjust a size of the coating solution outlet, the plurality of gap adjusting portions being arranged in a width direction of the base material.