Coating Tunnel Carrier Gas Loop Segmentation
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Solution Overview
Problem
Hollow glass containers face challenges in achieving a homogeneous coating distribution and reducing coating chemical consumption and emissions during high-speed production, as existing coating apparatuses suffer from material loss and dilution due to inefficient carrier gas management.
Innovation Solution
A coating apparatus with a specific partial separation of the carrier gas flow into two loops, where the carrier gas loaded with the coating compound is separated into a return loop and a recycle loop, allowing for reintegration into the coating process, thereby minimizing losses and enhancing coating efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the carrier gas flow is not separated into loops, then the coating compound is lost through exhaust and inlet, but the system structure remains simple
Solution Approach 1:
The carrier gas flow is segmented into two distinct loops: a first loop that recycles carrier gas from the outlet back to the inlet, and a second loop that introduces fresh carrier gas at the inlet and extracts it at the outlet. This segmentation allows the coating compound to be retained and reused in the first loop while the second loop provides necessary gas exchange, thereby reducing coating compound loss without creating a overly complex system.
2Quantity of substance
If fresh air is introduced at the inlet to maintain pressure, then the coating compound is diluted, but the pressure balance is maintained
Solution Approach 1:
The gas flow system is divided into two loops where the second loop specifically manages the fresh air introduction and exhaust extraction. This segmentation allows precise control over where fresh air enters and where exhaust leaves, minimizing unnecessary dilution of the coating compound while maintaining proper pressure balance in the coating tunnel.
Solution Approach 2:
The first loop provides continuous recycling of carrier gas containing the coating compound, ensuring that the coating compound remains concentrated and available for continuous coating application. This continuous recycling action maintains high coating compound concentration despite the presence of the second loop introducing fresh air.
3Productivity
If the coating compound concentration is increased to compensate for dilution, then more coating can be applied, but more coating compound is consumed and emitted
Solution Approach 1:
By segmenting the carrier gas flow into two loops, the system can maintain high coating compound concentration in the first recycling loop, enabling continuous coating application at optimal rates. The second loop's fresh air introduction is minimized and strategically positioned to avoid excessive dilution, thereby maintaining productivity without increasing coating compound consumption and emission.
Solution Approach 2:
The first loop recovers and recycles the carrier gas containing the coating compound that would otherwise be lost through the exhaust system. This recovery mechanism ensures that the coating compound is reused rather than discarded, maintaining high coating application rates while reducing overall coating compound consumption and emission to the environment.
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
This solution achieves a more homogeneous coating distribution, reduces coating chemical consumption, and lowers emissions by effectively recycling the coating compound, improving the overall efficiency of the coating process while minimizing the exchange with ambient air.
Implementation Method 1
The coating application is done inside a coating apparatus also called a coating tunnel or coating hood with a so called hot end coating by chemical vapor deposition usually in forming a thin layer of a metal oxide
Implementation Method 2
The coating compound is fed in the coating tunnel and circulates inside with the aid of a carrier gas around the passing glass containers
Data Source
Figure 1~2
Figure 3~3a
Figure 3b
AI summary
The present invention relates to a coating apparatus also called coating tunnel or coating hood for applying a protective coating to hollow glass containers. In particular it relates to a coating apparatus also called coating tunnel or coating hood with the re-use of the coating material containing exhaust from the end of the coating tunnel for applying the protective coatings to glass containers. More particularly the present invention relates to a coating apparatus also called coating tunnel or coating hood with a specific partial separation of the carrier gas flow of one loop into two respective loops.