Plasma Coating Station Power Distribution for Multi-Container Throughput
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Solution Overview
Problem
Conventional plasma coating technologies for containers are expensive due to inefficient power supply units and lack of simultaneous operation capability across multiple stations, leading to suboptimal coating quality and increased costs.
Innovation Solution
The apparatus employs a high-frequency generator and an a.c. voltage distribution device, such as a multiplexer, to distribute voltage pulses with a time delay to multiple coating stations independently, allowing for simultaneous operation and optimizing power usage by adjusting pulse power based on measured parameters, thereby reducing costs and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple coating stations are operated simultaneously with individual power supply units, then coating productivity is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple power supply units into a single shared power supply that can distribute power to multiple coating stations. The control unit manages power distribution to different stations sequentially or simultaneously, reducing the total number of power supply units needed while maintaining the ability to operate multiple stations independently.
Solution Approach 2:
The single power supply unit is designed to serve multiple coating stations through a control unit that can dynamically allocate power to different stations. This universal power supply system replaces multiple dedicated power supplies, reducing complexity while maintaining productivity.
2Manufacturing precision
If pulse power is increased to achieve complete gas molecule dissociation, then coating quality is improved, but energy consumption increases
Solution Approach 1:
The patent uses pulsed power delivery instead of continuous high power. The control unit delivers power in controlled pulses that achieve the necessary gas molecule dissociation for coating quality, then allows pause periods. This periodic action maintains coating quality while significantly reducing overall energy consumption compared to continuous high-power operation.
Solution Approach 2:
The control unit dynamically adjusts power parameters including pulse duration, pulse frequency, and power level based on process requirements. By optimizing these parameters, the system achieves complete gas molecule dissociation (necessary for coating quality) while minimizing energy consumption through precise parameter control rather than continuously high power settings.
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 reduces operational costs, enhances coating efficiency, and ensures consistent quality across multiple stations by optimizing power distribution and reducing the influence of individual station issues on others, leading to improved plasma coating processes.
Implementation Method 1
a silicon-containing precursor (for example HMDSO, HMDSM, TEOS or other Si-containing compounds) is vaporised and introduced together with oxygen into a vacuum. The gas molecules are then broken down more or less completely into their constituents by a plasma
Implementation Method 2
For the coating of surfaces with, for example, silicon oxide, usually plasma methods (PECVD=plasma-enhanced chemical vapour deposition) are generally used
Implementation Method 3
an a.c. voltage distribution device, which distributes this a.c. voltage respectively to at least one electrode of the first coating station and of the second coating station
Data Source
AI summary
Provided is an apparatus and a method for coating objects and in particular containers with at least one first and one second coating station, wherein these coating stations each have at least one first coating electrode and one second coating electrode, and with a supply device for electrical supply of in each case at least one of the coating electrodes. The supply device has a high-frequency generator device for generating an a.c. voltage and/or voltage pulses as well as an a.c. voltage distribution device which distributes this a.c. voltage and/or the voltage pulses respectively to in each case at least one electrode of the first coating station and at least one electrode of the second coating station, wherein the a.c. voltage distribution device is suitable and intended for distributing the a.c. voltages and/or the voltage pulses with a time delay to the electrodes.