Atmospheric Plasma Coating Device with Vaporizer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing plasma jet coating technologies face challenges in achieving homogeneous and reproducible layer properties under atmospheric conditions due to unwanted chemical and physical changes of coating materials, leading to inhomogeneous layer structures and reduced coating quality.
Innovation Solution
A device with a plasma generator that directs the plasma jet outlet into the surrounding atmosphere, allowing the coating material to be introduced into the outflow area where it can be ionized and chemically modified, enabling targeted control of layer properties and avoiding deposits in the outlet channel, with an adjustable feed tube positioning for precise control of coating material delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coating material is introduced into the plasma jet before it exits the outlet channel, then the coating material can be deposited on the substrate, but unwanted chemical reactions and deposits in the outlet channel occur leading to inhomogeneous layer structure
Solution Approach 1:
The coating material is vaporized in advance in an evaporator before being introduced into the plasma jet. This preliminary vaporization ensures that the coating material is already in gaseous form with controlled particle size, preventing unwanted chemical reactions and deposits in the outlet channel while achieving homogeneous layer structure on the substrate.
2Reliability
If coating is performed under vacuum to prevent chemical changes, then oxidation and hydrolysis are reduced, but equipment complexity and costs increase significantly
Solution Approach 1:
The invention changes the physical state parameter of the coating material from solid/powder to gas by using an evaporator. This parameter change allows the coating process to be performed at atmospheric pressure without unwanted chemical reactions, eliminating the need for complex vacuum equipment while maintaining reliable and consistent coating quality.
3Productivity
If powdered coating materials are fed via carrier gas, then the material can be delivered to the plasma jet, but particle size variation leads to inhomogeneous deposition
Solution Approach 1:
The invention uses phase transition by vaporizing the coating material in an evaporator, transforming it from solid or powdered state to gaseous state. This phase transition ensures uniform particle size and homogeneous distribution, enabling efficient and precise coating deposition without the particle size variation problems associated with powder feeding methods.
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 allows for more homogeneous deposition with thinner layer thicknesses, improved control over functional properties, and increased service life of the plasma generator by avoiding unwanted chemical reactions and deposits, resulting in higher reproducibility and homogeneity of the coating.
Implementation Method 1
a plasma generator (1) with a cathode (2) and an anode (5) for generating an atmospheric plasma jet (18) by electrical discharge in a working gas
Implementation Method 2
which ionizes the working gas and creates a plasma jet in the channel forms
Implementation Method 3
the supply device (13, 16) is connected to an evaporator (15) for the coating material on the inlet side and has an outlet opening (16) for the gaseous coating material on the outlet side
Data Source
Figure 1
AI summary
The invention relates to a device for applying a coating to a surface of a substrate by means of a plasma generator (1), comprising an anode (5) and a cathode (2) for generating an atmospheric plasma jet by electrical discharge in a working gas, wherein the plasma generator (1) has an outlet channel (4) for the plasma jet, which opens to the surrounding atmosphere via an outflow opening (14), to which an outflow region (14) of the plasma jet escaping into the surrounding atmosphere connects, and comprising is a feed apparatus having an inlet side for loading the feed apparatus with a coating material and an outlet side for introducing the coating material into the plasma jet. According to the invention, the feed apparatus is connected on the inlet side to a vaporizer (15) for the coating material and, on the outlet side, to an outlet opening (16) for the gaseous coating material, which is directed into the outflow region (14). As a result of the local variability of the material input into the plasma jet, in particular the functional properties of the coating can be more uniformly and better controlled.