Coating Nozzle Valve Control for Uniform Profiles
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Solution Overview
Problem
Existing coating application systems face issues with uneven coating profiles due to residual coating material in the nozzle, leading to excess material being left on the sheet, which causes unacceptable thickness variations and requires the use of a fluid suction mechanism for removal.
Innovation Solution
A controller-actuated system that precisely controls the valves and nozzle movement, allowing for the creation of various coating profiles without the need for a fluid suction mechanism, using a fluid displacement mechanism to alternately draw and replace a small volume of fluid through a conduit, ensuring precise control of coating application and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fluid suction mechanism is used to remove excess coating material from the nozzle, then coating uniformity is improved, but device complexity increases
Solution Approach 1:
The patent removes the fluid suction mechanism entirely from the system. Instead of using vacuum suction to remove excess coating, the system relies on precise valve control and nozzle design to prevent excess material accumulation in the first place, thereby simplifying the device while maintaining coating uniformity
Solution Approach 2:
The coating system is designed to be self-regulating through the interaction of the supply valve, bypass valve, and nozzle geometry. The system naturally prevents excess material buildup through controlled flow dynamics without requiring an additional active suction component
2Manufacturing precision
If the supply valve is closed to stop coating flow, then coating application is controlled, but residual coating material remains in the nozzle causing uneven application
Solution Approach 1:
The bypass valve is opened in advance before the supply valve is closed. This preliminary action allows coating material to continue flowing through the bypass line, preventing pressure buildup and ensuring that when the supply valve closes, minimal residual material remains in the nozzle, thus avoiding uneven coating at the start of the next application
Solution Approach 2:
The bypass valve acts as an intermediary flow path that manages the transition between coating application and cessation. It provides a controlled route for coating material to flow during valve transitions, mediating between the supply valve closure and the nozzle to prevent material accumulation
3Manufacturing precision
If the nozzle is moved relative to the roller to minimize coating material, then coating precision is improved, but productivity decreases due to additional movement time
Solution Approach 1:
Instead of completely retracting the nozzle from the roller to minimize coating material, the system uses partial valve closure and bypass flow to achieve the same effect with the nozzle remaining in its optimal coating position. This allows continuous coating operation without the productivity loss associated with nozzle retraction and repositioning
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 system achieves precise control over coating profiles, eliminating the need for a fluid suction mechanism, allowing for high production rates with controlled starting and ending profiles, and accommodating changes in line speed, while ensuring even coating application without excess material accumulation.
Implementation Method 1
a fluid suction mechanism 80′ may be used, as shown in FIG. 1. This fluid suction mechanism is used to draw the excess coating that is left in the manifold 71 or on the lips 72 of the nozzle 70
Implementation Method 2
The coating is drawn from the reservoir 30, through conduit 31 by pump 40. The coating is then passed through conduit 32 by the action of the pump 40
Implementation Method 3
In the case where coating is not being applied to the sheet 10, bypass valve 50 is open while supply valve 60 is closed. This allows the coating that is pumped through conduit 32 to pass through conduit 33 and back to reservoir 30
Data Source
AI summary
An improved system for applying a coating to a sheet is disclosed. The system allows precise control of the actuation of the valves and movement of the nozzle to create a plurality of coating profiles. The system includes a controller, which is used to actuate the valves to begin and terminate the flow of material onto the sheet through a nozzle. In addition, the controller may move the nozzle from its operative position to an inoperative position away from the sheet. In some embodiments, a fluid displacement mechanism is used. The controller is also able to coat the opposite side of the sheet. Registration of the coating can be programmed to be in exact alignment, or advanced or delayed by a specific amount.