Multi-Tank Batch Coating Apparatus for Uniform Electrode Films
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Solution Overview
Problem
Existing batch coating processes for medical instruments, such as implantable blood glucose monitors, face challenges in achieving uniformity and consistency of the coating film due to various parameters affecting the thickness, opacity, and color of the film-forming layer on sensor electrodes.
Innovation Solution
A batch coating apparatus comprising a fixing mechanism, liquid holding mechanism, and liquid injection mechanism, controlled by a control device, to ensure precise immersion and withdrawal of work-pieces in a uniform coating liquid, forming a predetermined thickness on the electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a pulling coating apparatus is used to dip sensor electrodes into sol and pull them out to form coating film, then the coating process can be performed, but the thickness, opacity and color of the film-forming layer vary significantly due to large number of variables affecting coating parameters
Solution Approach 1:
The coating apparatus is divided into multiple independent liquid tanks, each containing a specific coating liquid. This segmentation allows independent control of each coating liquid's parameters (volume, depth, composition) and enables simultaneous coating of multiple electrodes with consistent results, reducing the impact of variable interactions.
Solution Approach 2:
The patent controls and optimizes key coating parameters including liquid tank volume, coating liquid depth, dipping speed, and electrode orientation. By systematically adjusting these parameters and maintaining them within specific ranges, the apparatus achieves uniform coating thickness and consistency across multiple electrodes.
2Reliability
If multiple variables are present in the coating process, then the coating can be performed, but it becomes difficult to ensure uniformity of the coating film
Solution Approach 1:
The apparatus incorporates control mechanisms that monitor and adjust coating parameters in real-time. The control device regulates liquid injection rates, tank filling levels, and electrode movement speeds to maintain optimal coating conditions, ensuring consistent film formation across multiple electrodes.
Solution Approach 2:
Coating liquids are prepared and filled into liquid tanks before the coating process begins. The apparatus pre-adjusts liquid levels, temperatures, and compositions to ensure optimal conditions are established beforehand, eliminating variability during the actual coating operation.
3Productivity
If batch coating is implemented to improve efficiency, then productivity increases, but controlling the uniformity of coating film becomes more difficult
Solution Approach 1:
The apparatus uses multiple liquid tanks arranged side by side, with each tank dedicated to a specific coating liquid. This segmentation allows simultaneous batch coating of multiple electrodes while maintaining independent control over each coating liquid's parameters, ensuring uniformity across all coated electrodes.
Solution Approach 2:
The apparatus is designed as a multi-functional system that can handle multiple coating liquids, multiple electrodes, and various coating configurations simultaneously. The universal design with adjustable tanks and control mechanisms enables batch processing while maintaining precision through standardized procedures.
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 enhances the uniformity and consistency of the coating film on medical instruments by controlling the relative movements and liquid supply, improving the stability and accuracy of the coating process.
Implementation Method 1
the control device controls the liquid holding mechanism and the fixing mechanism to relatively move so that the work-pieces to be coated fixed to the fixing mechanism are immersed into the coating liquid in the plurality of liquid tanks and left from the coating liquid in the plurality of liquid tanks
Implementation Method 2
with the rapid evaporation of a solvent in the sol, a uniform thin film is formed on the surface of the sensor electrode infiltrated by the sol
Data Source
AI summary
Some embodiments of the disclosure describe a batch coating apparatus. In some examples, the batch coating apparatus includes a fixing mechanism, a liquid holding mechanism, a liquid injection mechanism and a control device. The fixing mechanism includes a plurality of fixing portions for fixing work-pieces to be coated. The liquid holding mechanism includes a plurality of liquid tanks arranged side by side. The liquid injection mechanism includes a liquid storage portion and an infusion portion. The control device is configured to control at least one of a relative movement between the fixing mechanism and the liquid holding mechanism and a relative movement between the liquid holding mechanism and the liquid injection mechanism. The control device is configured to control the liquid injection mechanism to supply the coating liquid via the infusion portion.