Coating Apparatus Liquid Cut-off Control via Suck Back Valve
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Solution Overview
Problem
Current coating apparatuses face challenges in controlling 'liquid cut-off' efficiently when foreign substance removable filters are placed between the nozzle and open/close valve, leading to uneven coating and increased operating time, and chemical spillage during filter replacement.
Innovation Solution
A coating apparatus with an open/close valve and suck back valve driven by electric signals, allowing precise control of liquid cut-off and incorporating a joint mechanism that prevents chemical spillage during filter replacement by positioning the downstream joint higher than the nozzle opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a foreign substance removable filter is provided between the nozzle and the open/close valve, then foreign substance removal is improved, but chemical dripping occurs due to residual pressure in the filter
Solution Approach 1:
A suck back valve is introduced as an intermediary component between the foreign substance removable filter and the open/close valve. This mediator allows residual chemical to be suctioned back into the filter when the open/close valve closes, preventing dripping while maintaining the filter's foreign substance removal function.
2Ease of operation
If manual speed controllers are used to control liquid cut-off for each nozzle, then individual nozzle control is achieved, but excessive operating time is required
Solution Approach 1:
Manual mechanical speed controllers are replaced with an automated control system using electric signals. The controller automatically adjusts the suck back valve and open/close valve for each nozzle based on pre-programmed parameters, eliminating manual operation while maintaining individual nozzle control capability.
Solution Approach 2:
The system enables self-service operation where the controller automatically manages liquid cut-off for multiple nozzles without requiring operator intervention for each nozzle. The automated coordination of valves and timing allows the system to service itself through programmatic control.
3Productivity
If multiple coating apparatus are provided to perform the same process, then production capacity is increased, but machine differences make consistent control difficult
Solution Approach 1:
The control system is designed with universal applicability across multiple coating apparatus. The same controller and valve coordination mechanism can be applied to any number of coating stations, ensuring consistent liquid cut-off performance across all machines in the series without requiring machine-specific adjustments.
4Reliability
If the foreign substance removable filter is placed adjacent to the nozzle, then foreign substance removal effectiveness is improved, but control of liquid cut-off becomes complex
Solution Approach 1:
The suck back valve and open/close valve functions are merged into a coordinated control sequence managed by a single controller. This integration simplifies the overall control architecture despite the filter's proximity to the nozzle, as the automated coordination eliminates the need for complex manual adjustment mechanisms.
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 simple and rapid control of liquid cut-off across multiple nozzles and substrates, reducing machine differences and preventing chemical spillage during filter replacement, thus enhancing production efficiency and yield.
Implementation Method 1
a suck back valve provided between the nozzle and the open/close valve... a suck back valve used for avoiding the dripping
Implementation Method 2
a foreign substance removable filter is provided between the open/close valve and the pump for removal of foreign substances
Data Source
AI summary
A coating apparatus includes an open/close valve having a motor that allows control of opening operation and closing operation in accordance with electric signals applied from a controller. The coating apparatus further includes a suck back valve having a motor that allows control of a volume variation in a flow path for suck back that is in communication with an upstream side and a downstream side of a pipe in accordance with electric signals from the controller. The controller allows control of start of the closing operation of the open/close valve and start of suction operation of the suck back valve through application of the electric signals to the respective motors. This achieves simple adjustment of liquid cut-off.