Guide Plate Vapor Distributor for Uniform Steel Vacuum Coating
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Solution Overview
Problem
Existing vacuum coating technologies fail to achieve uniform coating thickness on steel surfaces, which is crucial for subsequent processes like bending and punching.
Innovation Solution
A vacuum coating device using a guide plate type structure, comprising a crucible with an induction heater, a core rod with guide plates, a pressure stabilizing plate, and a coating nozzle, to uniformly distribute and guide metal steam for uniform coating on steel plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional nozzle structures (integrated or separated crucible-nozzle) are used, then the coating process can be simplified, but the coating thickness uniformity deteriorates
Solution Approach 1:
The flow distribution tank body is segmented into multiple functional zones using guide plates arranged in concentric circles. The guide plates divide the tank into first, second, and third flow distribution areas, each with different flow characteristics. This segmentation allows independent optimization of metal steam flow in different regions, achieving uniform coating thickness while maintaining a relatively simple overall structure.
Solution Approach 2:
Different regions of the flow distribution tank are given different local characteristics through the guide plate arrangement. The first guide plate creates a first flow distribution area with specific flow patterns, the second guide plate creates a second area with different flow characteristics, and the third guide plate creates a third area. Each region is optimized for its specific function, allowing the entire system to achieve uniform coating distribution.
2Productivity
If metal steam is sprayed directly onto the steel plate, then the coating process is fast, but the coating thickness is non-uniform
Solution Approach 1:
The metal steam undergoes preliminary flow distribution and uniformization within the flow distribution tank body before being sprayed onto the steel plate. The guide plates pre-arrange the metal steam flow into three distinct flow distribution areas, ensuring uniform distribution before the coating deposition step. This preliminary action maintains high coating speed while achieving uniform thickness.
Solution Approach 2:
The flow distribution tank body acts as an intermediary between the metal steam source and the steel plate substrate. It mediates the metal steam flow by using guide plates to create controlled flow distribution patterns, transforming the direct spray into a uniformly distributed flow that deposits evenly on the steel plate surface.
3Manufacturing precision
If guide plates are added to distribute metal steam, then coating uniformity improves, but device complexity increases
Solution Approach 1:
The guide plates are segmented into three distinct sets (first, second, and third guide plates) arranged in concentric circles within the flow distribution tank. Each set creates a specific flow distribution area with unique characteristics. This segmentation approach achieves complex flow control functionality while keeping each individual guide plate component simple and manufacturable.
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 ensures uniform distribution and formation of metal coatings on steel plates, enhancing the quality and consistency of subsequent processing steps.
Implementation Method 1
an induction heater for heating a molten metal in the crucible to form metal steam
Implementation Method 2
heated under vacuum conditions, so that it is deposited in a gaseous state onto a substrate
Implementation Method 3
Physical vapor deposition (PVD) refers to a process technique that a plated metal is heated under vacuum conditions, so that it is deposited in a gaseous state onto a substrate to form a coating
Implementation Method 4
a pressure stabilizing plate, which extend in a horizontal direction, are arranged inside the flow distribution tank body
Data Source
AI summary
Disclosed in the present invention is a vacuum coating device for uniformly distributing metal steam by using a guide plate type structure. The vacuum coating device comprises a crucible, wherein an induction heater for heating molten metal in the crucible to form metal steam is arranged outside of the crucible. A top of the crucible is connected to a flow distribution tank body by means of a metal steam pipeline. A horizontal core rod and a pressure stabilizing plate are arranged inside the flow distribution tank body. The core rod is located below the pressure stabilizing plate. A coating nozzle is arranged at the top of the flow distribution tank body. An induction coil is arranged on the outer side of the flow distribution tank body. A pressure regulating valve is arranged on the metal steam pipeline. A plurality of axial heating holes are provided inside the core rod, resistance wires are arranged inside the heating holes, and a primary guide plate, a secondary guide plate and a tertiary guide plate are arranged on the surface of the core rod; and a buffer groove is provided on the inner wall of the flow distribution tank body, and the buffer groove corresponds to the core rod in position. According to the present invention, when high-temperature steam makes contact with a low-temperature steel plate, a uniform coating is formed on the surface of the steel plate.