Plasma Coating Station Pulse Distribution for Independent Operation

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Solution Overview

Problem

Existing plasma coating devices for containers are cost-intensive due to inefficient power supply utilization and interdependence between plasma stations, leading to high operational costs and reduced efficiency.

Innovation Solution

A device with multiple coating stations supplied by a single high-frequency generator, utilizing a multiplexer to distribute voltage pulses with a time offset, allowing independent operation of each station and optimizing power usage based on measured values for efficient plasma coating.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple coating stations are operated simultaneously with separate power supplies, then coating productivity is improved, but device complexity and operational costs increase

Engineering Contradiction:
Improvecoating productivityVSAvoiddevice complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent combines multiple coating stations into a single vacuum chamber and supplies them with a common power supply unit. This merging approach allows simultaneous operation of multiple stations (improving productivity) while reducing the number of power supplies needed (reducing device complexity and costs). The stations share common infrastructure including vacuum pumping and power supply, eliminating the need for separate systems at each station.

Inventive Principle:
Principle #5Merging (Combining)

2Productivity

If plasma pulses are supplied to multiple coating stations simultaneously, then coating efficiency is improved, but interference between stations occurs

Engineering Contradiction:
Improvecoating efficiencyVSAvoidprocess stability
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The patent implements periodic, time-multiplexed plasma pulsing where each coating station receives plasma pulses in sequence rather than simultaneously. The control unit coordinates the timing so that stations are pulsed alternately with sufficient pause periods between them. This periodic action allows multiple stations to operate efficiently within the same vacuum chamber while preventing plasma interference and ensuring stable, reliable coating processes at each station.

Inventive Principle:
Principle #19Periodic action

3Adaptability or versatility

If separate power supplies are used for each coating station, then process independence is improved, but operational costs and energy consumption increase

Engineering Contradiction:
Improveprocess independenceVSAvoidenergy consumption
Core Design Contradiction:
Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The patent makes the single power supply unit universal by enabling it to supply plasma pulses to multiple different coating stations through time-multiplexed control. The power supply can be dynamically assigned to different stations based on process requirements, providing adaptability and independence for each station's coating process while sharing the same energy source. This multi-functional approach reduces total energy consumption compared to having dedicated power supplies for each station.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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 costs, enhances efficiency, and allows for simultaneous operation of multiple stations without interference, improving the overall plasma coating process while minimizing power consumption.

Implementation Method 1

The gas molecules are usually broken down by supplying energy, for example by intensive electromagnetic radiation, such as microwave, high frequency or low frequency (by forming a plasma)

Methodology Applied
Scientific EffectHigh-frequency electromagnetic radiation: Electromagnetic Induction

Implementation Method 2

The gas molecules are then more or less completely broken down into their components by a plasma and then recombine to form new compounds, including SiOs, which are deposited on the surface

Methodology Applied
Scientific EffectPlasma: Plasma

Implementation Method 3

an alternating voltage distribution device, which distributes this alternating voltage to at least one electrode of the first coating station and the second coating station

Methodology Applied
Scientific EffectElectrical pulse distribution: Electrical Resistance

Data Source

PatentEP3671805B1Device and method for coating and especially for plasma coating containers
Publication Date: 2023.09.13 KRONES AG
  • EP3671805B1 patent drawingFigure 1~2
  • EP3671805B1 patent drawingFigure 3

AI summary

Device for coating objects (10) and in particular containers (10) with at least one first and one second coating station (2, 4), wherein these coating stations (2, 4) each have at least one first coating electrode (22, 42) and one second coating electrode (24, 44) and a supply device (6) for supplying electrical power to at least one of the coating electrodes (22, 24).According to the invention, the supply device (6) comprises a high-frequency generator device (62) for generating an alternating voltage and/or voltage pulses (P, P2, P4, P20, P40) and an alternating voltage distribution device (64) which distributes this alternating voltage and/or the voltage pulses (P, P2, P4, P20, P40) to at least one electrode of the first coating station (2) and at least one electrode of the second coating station (4), wherein the alternating voltage distribution device is suitable and intended to distribute the alternating voltages and/or the voltage pulses (P, P2, P4, P20, P40) to the electrodes with a time offset.