Metal Vapor Mixing Buffer Structure for Uniform Vacuum Coating
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Solution Overview
Problem
Existing vacuum coating technologies struggle to achieve uniform thickness distribution of metal coatings on steel surfaces, which is crucial for subsequent processes like bending and punching.
Innovation Solution
A vacuum coating apparatus utilizing a uniform mixing buffer structure with a crucible, induction heater, uniform mixing groove, pressure stabilizing plate, and coating nozzle, which includes features like axial heating holes, overflow holes, and deceleration walls to distribute and stabilize metal steam before spraying, ensuring uniform coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional nozzle structures (integrated or separated crucible-nozzle designs) are used, then the coating process can be performed, but uniform metal steam distribution cannot be achieved, resulting in non-uniform coating thickness
Solution Approach 1:
The flow distribution tank body is segmented into multiple functional zones: a uniform mixing groove for primary distribution, a buffer groove with deceleration walls for velocity reduction, and a pressure stabilizing plate for pressure equalization. This segmentation allows each zone to perform its specific function, achieving uniform metal steam distribution through a series of simplified stages rather than a single complex nozzle structure.
Solution Approach 2:
The uniform mixing groove acts as an intermediary structure between the metal steam pipeline and the coating nozzle. It receives metal steam from the pipeline, performs uniform mixing and initial distribution, then delivers the uniformly distributed steam to the coating nozzle. This intermediary structure resolves the contradiction by providing a intermediate stage for uniformization without requiring the final nozzle to be overly complex.
2Productivity
If high velocity metal steam spraying is used for efficient coating, then productivity is improved, but coating uniformity deteriorates due to uneven steam distribution
Solution Approach 1:
The uniform mixing groove performs preliminary uniform distribution of metal steam before the steam reaches the coating nozzle. By pre-distributing the steam uniformly in the mixing groove, the system ensures that when high-velocity spraying occurs at the nozzle, the uniformity is already established, allowing both high productivity and uniform coating quality.
Solution Approach 2:
The buffer groove with deceleration walls provides beforehand cushioning by reducing the velocity of metal steam before it enters the pressure stabilizing plate and coating nozzle. This velocity reduction prevents turbulence and uneven distribution that would occur with direct high-velocity injection, allowing the system to maintain high overall productivity while achieving uniform coating through controlled, uniform steam delivery.
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 achieves uniform metal coating on steel surfaces by primary and secondary buffered distribution, enhancing the quality and consistency of the coating process.
Implementation Method 1
a plated metal is heated under vacuum conditions, so that it is deposited in a gaseous state onto a substrate
Implementation Method 2
an induction coil arranged outside the flow distribution tank body
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
Data Source
AI summary
Disclosed in the present invention is vacuum coating apparatus for uniformly distributing metal steam using a uniform mixing buffer structure, comprising 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.