Helical Corona Electrode Array for Uniform Wide-Web Plasma Treatment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current corona treatment machines are limited in treating large width materials due to electrode geometry and inconsistent treatment resulting from varying electrode speeds and radii, leading to uneven surface treatment and potential material damage.
Innovation Solution
A corona treatment machine with a helical electrode array arranged along a central conductive cylinder, where high frequency, high voltage power ionizes air to create a plasma corona, and a contact plate directs the electrical discharge, ensuring consistent treatment across larger material widths with reduced electrode wear and power usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electrodes are arranged on a circular plate at various distances from the central shaft, then the plasma corona can be dispersed across the material, but the treatment becomes inconsistent due to varying electrode speeds and radii
Solution Approach 1:
The electrode array is segmented into multiple individual electrodes positioned at different radial distances from the central shaft. Each electrode operates independently, allowing the system to treat wider materials by distributing the plasma corona across multiple electrode positions rather than relying on a single continuous electrode.
Solution Approach 2:
The circular plate rotates about the central shaft, creating dynamic motion that disperses the plasma corona curtain widthwise across the material. This rotational dynamics enables consistent treatment across varying material widths by continuously adjusting the electrode-material interaction.
2Reliability
If high voltage electrical discharge is used to energize the surface, then the surface treatment effectiveness is improved, but the material may be damaged due to uneven treatment
Solution Approach 1:
The electrode array provides localized plasma corona discharge at multiple discrete electrode positions rather than a single intense discharge point. This distributes the energy application across the material surface, achieving effective surface treatment while preventing concentrated damage to any single area.
Solution Approach 2:
The patent replaces conventional mechanical or thermal surface treatment methods with plasma corona discharge. This electrical field-based approach energizes the surface without the mechanical contact or thermal stress that could cause material damage.
3Reliability
If flame or high voltage electrical sparks are used for surface treatment, then the surface energization is achieved, but the treatment is uneven and inappropriate for most industrial applications
Solution Approach 1:
The patent substitutes uncontrolled flame or spark discharge with a controlled plasma corona field generated by the rotating electrode array. This creates a more uniform and controllable treatment process suitable for industrial applications while maintaining effective surface energization.
Solution Approach 2:
The rotating electrode array provides continuous plasma corona discharge as it rotates, ensuring uninterrupted and uniform surface treatment. This continuous action eliminates the intermittent and uneven treatment characteristic of flame or spark methods.
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 machine efficiently treats materials with large cross-sectional heights and widths, providing consistent plasma corona treatment with reduced wear and lower power consumption, while accommodating varying material sizes and thicknesses.
Implementation Method 1
The high frequency, high voltage power ionizes the air surrounding the electrodes and creates a plasma corona used to energize the surface of various materials.
Implementation Method 2
A power generator and high voltage transformer are connected to an electrode and create enough electrical potential to cross an airgap producing a visible plasma corona aura.
Implementation Method 3
a dielectric is placed between the electrode array and the contact plate
Data Source
AI summary
A corona/plasma treatment machine includes an array of electrodes arranged in a helix along a conductive central cylinder, allowing for the efficient surface treatment of materials with greater cross-sectional heights and widths than what is conventionally possible. The corona/plasma treatment machine further includes of a high frequency, high voltage power source, a dielectric, and a contact plate. The array of electrodes is driven using a motor and rotates about its longitudinal axis and is electrically isolated from its surroundings. When power is supplied to the electrode array, electrical energy is discharged from the tips of the electrodes near the contact plate and creates a plasma corona aura formed from the ionization of the surrounding air between the electrode array and the contact plate. A conveyor is positioned below the electrode array and configured to feed material through the plasma corona aura.