Coating Device Roller Doctor Blade Gap Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Automated coating processes face issues with excess coating agent accumulation and uneven application on non-uniform surfaces, leading to contamination and inefficiencies in roller rotation, which require frequent cleaning or replacement and complex programming for varying part shapes.
Innovation Solution
A coating device with a roller that includes a supply system with doctor blades to manage coating agent flow, tilt adjustment for uneven surfaces, and friction members to ensure synchronous rotation and uniform application, along with a controller to synchronize speed and adjust friction forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a roller is used to apply coating agent to member surfaces, then coating operation can be automated, but excess coating agent accumulates on the roller causing contamination and requiring frequent cleaning or replacement
Solution Approach 1:
The patent extracts the excess coating agent from the roller surface using a doctor blade that scrapes off the surplus coating material. This prevents accumulation and contamination while maintaining automated operation, directly resolving the contradiction between automation and harmful accumulation.
Solution Approach 2:
The system discards excess coating agent by scraping it off with a doctor blade, preventing it from accumulating on the roller. This continuous removal process maintains clean roller surfaces during automated operation, eliminating the need for frequent cleaning or replacement.
2Force
If the roller rotational friction is large, then the roller can maintain contact with the surface, but the roller slips and does not synchronously rotate causing uneven coating thickness
Solution Approach 1:
The patent makes the roller support structure dynamic by allowing the roller to be tilted in pitch and roll directions. This dynamic adjustment capability enables the roller to adapt to surface variations while maintaining optimal contact, preventing slip and ensuring synchronous rotation for uniform coating thickness.
Solution Approach 2:
The system changes the roller's orientation parameters (pitch angle and roll angle) to optimize contact with the member surface. By adjusting these parameters, the roller maintains appropriate friction for contact while preventing excessive friction that would cause slipping and uneven coating.
3Adaptability or versatility
If the roller is used on tilted, stepped or uneven surfaces, then coating can be applied to various part shapes, but complex programming is required for each part
Solution Approach 1:
The patent implements dynamic tilt adjustment capability in the roller support, allowing automatic adaptation to various part geometries. This dynamic adjustment replaces complex programming with real-time mechanical adaptation, maintaining versatility while reducing device complexity.
Solution Approach 2:
The roller support system performs self-adjustment by automatically tilting the roller to match the member surface geometry. This self-service capability eliminates the need for complex external programming, allowing the system to adapt to various part shapes autonomously.
4Quantity of substance
If over-coating is performed to achieve required thickness, then sufficient coating coverage is obtained, but the roller does not rotate synchronously due to low friction causing uneven application
Solution Approach 1:
The doctor blade extracts excess coating agent from the roller surface, preventing over-coating. This ensures that only the required amount of coating is transferred to the member, maintaining both sufficient coverage and uniform thickness without causing roller slip.
Solution Approach 2:
The system changes the coating agent viscosity parameter to optimize the balance between sufficient coating thickness and preventing roller slip. By adjusting viscosity, the coating provides enough friction for roller rotation while achieving the required thickness without over-coating.
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 device stably applies coating agents with controlled thickness and prevents excess accumulation, allowing for efficient coating on inclined or uneven surfaces without the need for frequent roller changes or complex programming, ensuring consistent and uniform coverage.
Implementation Method 1
If a rotational friction of the roller is large, the roller slips on a member surface
Implementation Method 2
a first doctor blade which is provided at the side of the opening on a rotation exit side of the roller; and a second doctor blade which is provided at the side of the opening on a rotation entry side of the roller
Data Source
AI summary
The objective of the present invention is to provide a coating device capable of stably coating a coating agent onto a member to be coated, while preventing the supply of excess coating agent. A coating device is provided with: a roller which rotates in one direction; a tank in which an opening is formed facing the roller and which supplies a coating agent via the opening; a doctor blade provided at the side of the opening on the rotation exit side of the roller; and a doctor blade provided at the side of the opening on the rotation entry side of the roller; wherein a gap formed between the doctor blade and the roller is larger than a gap formed between the doctor blade and the roller.