Lacquer Basin Diversion Element for Dip Coating Turbulence
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Solution Overview
Problem
Conventional dip coating devices for ophthalmic lenses often result in turbulent flows of lacquer mixture, leading to non-homogeneous coatings with defects and increased manufacturing costs due to the injection of lacquer mixture from the bottom of the lacquer basin, which creates turbulence and makes achieving uniform thickness challenging.
Innovation Solution
The introduction of a lacquer basin with a diversion element at the transition from the inlet to the process section, featuring multiple barrier layers with recesses that divert and calm the lacquer mixture flow, ensuring a laminar flow in the process section, reducing turbulence and contaminants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If lacquer mixture is injected from the bottom of the lacquer basin, then the coating process can be continuously performed, but turbulent flow occurs leading to non-homogeneous coatings
Solution Approach 1:
A diversion element is introduced as an intermediary component between the inlet section and process section. This diversion element includes a barrier layer with recesses that acts as a mediator to calm the turbulent lacquer mixture flow from the injection nozzle before it enters the coating process section, thereby eliminating turbulence without interrupting continuous operation
Solution Approach 2:
The lacquer basin is segmented into distinct functional sections: an inlet section for turbulent flow, a diversion element with barrier layers to calm the flow, and a process section for homogeneous coating. This segmentation allows each section to perform its specific function optimally while maintaining continuous operation
2Area of stationary object
If the lacquer basin dimensions are larger than the injection nozzle, then sufficient coating area is provided, but turbulence increases making homogeneous coating difficult
Solution Approach 1:
The diversion element serves as an intermediary zone between the small injection nozzle and the large lacquer basin. The barrier layer with recesses in the diversion element gradually dissipates the velocity and turbulence of the injected lacquer mixture before it expands into the larger process section, enabling uniform coating across the entire area
Solution Approach 2:
The diversion element changes the flow parameters of the lacquer mixture by reducing velocity and eliminating turbulence through the barrier layer structure. This parameter transformation allows the lacquer to transition from high-velocity turbulent flow at the nozzle to low-velocity laminar flow in the process section
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 approach enhances coating homogeneity, reduces defects, and lowers manufacturing costs by maintaining a laminar flow, thereby improving the quality and consistency of ophthalmic lens coatings.
Implementation Method 1
the injection of the lacquer mixture from an injection nozzle at the bottom of the lacquer basin and the larger dimensions of the lacquer basin compared to the injection nozzle often result in a turbulent flow of the stream of lacquer mixture in the lacquer basin
Implementation Method 2
ensuring a laminar flow in the process section, reducing turbulence and contaminants
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
A lacquer basin (12) for a dip coating device (10) is provided. The lacquer basin (12) comprises an inlet section (12a) arranged at a lower end of the lacquer basin (12) and adapted to receive a stream of a lacquer mixture (14) injected into the lacquer basin (12). The lacquer basin (12) further comprises a process section (12b) adjoining the inlet section (12a) at an upper end of the inlet section (12a), wherein the process section (12b) is adapted to provide a process volume for dip coating one or more objects in the stream of the lacquer mixture (14). The lacquer basin (12) is characterized in that it comprises a diversion element (22) arranged at or near a transition from the inlet section (12a) to the process section (12b) and adapted to divert at least a part of the stream of the lacquer mixture (14) such as to reduce or avoid turbulences of the stream of lacquer mixture (14) in the process section (12b). The lacquer basin (12) is characterized in that the diversion element (22) comprises two or more barrier layers (24) arranged at different levels spaced apart from each other, wherein each of the barrier layers (24) has multiple recesses (28) and intermittently covers the cross sectional area of the lacquer basin (12)