Continuous Coating Apparatus with Electromagnetic Levitation Heating
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Solution Overview
Problem
Existing coating technologies face limitations in coating high melting point materials and achieve low coating speeds due to heat loss and inefficiencies in evaporation methods, particularly with thermal evaporation and electron beam evaporation techniques, which restrict the application to low melting point materials and result in reduced coating speeds and increased costs.
Innovation Solution
A continuous coating apparatus that supplies molten metal to a levitation-heating space using electromagnetic coils, allowing for high-speed coating by generating evaporation vapor without heat loss, with the ability to control the supply flow rate and simplify the coating process by using a vacuum chamber, crucible, and vapor guide unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermal evaporation technique is used to coat low melting point materials, then coating can be performed, but coating speed is limited to mere 30 μm·m/min
Solution Approach 1:
The patent replaces the conventional thermal evaporation heating system with an electromagnetic levitation and heating system. The electromagnetic field generates eddy currents within the coating material, producing intense localized heating that rapidly vaporizes the material. This substitution of heating mechanism enables coating speeds exceeding 30 μm·m/min while successfully coating high melting point materials that cannot be processed by conventional thermal evaporation.
Solution Approach 2:
The patent utilizes phase transitions of the coating material through electromagnetic heating. The electromagnetic field rapidly heats the coating material from solid to liquid and then to vapor phase, enabling controlled evaporation and deposition onto the substrate. This phase transition approach allows precise control over the coating process while achieving high coating speeds.
2Productivity
If electron beam evaporation technique is used to vaporize coating material, then high melting point materials can be coated, but heat loss to crucible reduces energy efficiency and coating speed to merely 20 μm·m/min
Solution Approach 1:
The patent extracts the coating material from the conventional crucible-based electron beam evaporation system and suspends it in an electromagnetic field for levitation and heating. By removing the crucible contact, the system eliminates heat loss to the crucible walls and base, achieving energy efficiency exceeding 90%. The electromagnetic field directly heats the coating material through induced eddy currents, enabling coating speeds greater than 20 μm·m/min without energy waste to supporting structures.
Solution Approach 2:
The patent introduces an electromagnetic field as an intermediary between the energy source and the coating material. The electromagnetic field serves as the medium that transfers energy to the coating material through eddy current induction, enabling contactless heating and vaporization. This intermediary approach eliminates direct thermal contact with crucibles, preventing heat loss while maintaining efficient energy transfer to achieve high coating speeds.
3Adaptability or versatility
If solid wire feeder is used to supply coating material, then material can be supplied, but supply path is limited to lateral side only
Solution Approach 1:
The patent replaces the mechanical solid wire feeder system with a liquid coating material supply system. The liquid coating material is pumped through flexible tubing to the evaporation zone where it is rapidly vaporized by the electromagnetic field. This substitution enables supply from multiple directions (front, rear, left, right) rather than being restricted to lateral wire feeding, significantly improving supply path flexibility while simplifying the overall material delivery mechanism.
4Productivity
If solid wire is supplied to alternating electromagnetic field space, then levitation and heating occur, but coating speed is reduced or cost increases due to increased heating load
Solution Approach 1:
The patent changes the physical state parameter of the coating material from solid to liquid form. The liquid coating material requires significantly less heating load compared to solid wire because it already处于熔融状态. When supplied to the electromagnetic field, the liquid material vaporizes more efficiently and rapidly, achieving higher coating speeds without excessive energy consumption. This parameter change optimizes both productivity and energy efficiency.
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 apparatus enables high-speed, efficient coating of continuously moving metal strips with improved workability and precision, reducing costs by using molten metal and minimizing heat loss, while allowing for flexible supply paths and precise control of the coating material flow.
Implementation Method 1
a levitation-heating unit disposed in the vacuum chamber unit and generating an evaporation vapor by vaporizing a supplied coating material
Implementation Method 2
The levitation-heating unit may include one or more electromagnetic coils which levitate and heat the supplied coating material by an electromagnetic force
Implementation Method 3
a vacuum chamber unit through which a coating target passes
Implementation Method 4
a coating material is heated to a levitation state through an alternating electromagnetic field which is generated when a high-frequency alternating current is applied to an electromagnetic coil enclosing the coating material. Thus, metal (coating) vapors are generated
Data Source
AI summary
Provided is a continuous coating apparatus which can supply a liquid coating material (a molten metal) to a levitation-heating space through various paths, and can easily control a supply flow rate of the liquid coating material, and has a simplified structure. The continuous coating apparatus includes: a vacuum chamber unit through which a coating target passes; a levitation-heating unit disposed in the vacuum chamber unit and generating an evaporation vapor by vaporizing a supplied coating material; and a liquid coating material supply unit connected so that a liquid coating material is supplied to at least one of an upper portion and a lower portion of the levitation-heating unit, and communicating with the outside of the vacuum chamber unit.