Replaceable Coating Cartridge With Recirculation for Fast Coating Changes
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Solution Overview
Problem
Existing coating systems for optical articles face challenges in efficiently switching between different coatings due to batch manufacturing processes, making it difficult and time-consuming to change the type of coating applied.
Innovation Solution
A replaceable cartridge system with a reservoir, recirculation loop, and dual pumps is introduced, allowing for continuous recirculation and selective aspiration of coatings, featuring a diaphragm pump for circulation and a positive displacement piston pump for delivery, along with optional filtering and debubbling systems to maintain coating quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a batch manufacturing process is used for coating optical articles, then a single coating type can be applied efficiently to a batch, but it becomes difficult and time-consuming to change the coating type for subsequent batches
Solution Approach 1:
The coating system is segmented into a permanent coating applicator and replaceable cartridges containing different coatings. Each cartridge is a self-contained unit that can be quickly swapped between batches, allowing the applicator to maintain its optimized position and operation while the coating type changes with the cartridge replacement.
Solution Approach 2:
The coating material is extracted from the main system and placed into separate replaceable cartridges. This extraction allows the coating type to be changed by simply replacing the cartridge rather than changing the entire coating system, resolving the conflict between maintaining efficient batch processing and enabling coating type flexibility.
2Adaptability or versatility
If a replaceable cartridge system is implemented to enable switching between multiple coatings, then coating flexibility is improved, but the device complexity increases due to additional components like dual pumps and recirculation loops
Solution Approach 1:
The cartridge integrates multiple functions into a single replaceable unit: the reservoir, first pump for recirculation, second pump for delivery, filter, and debubbling system are all combined in one cartridge. This merging reduces overall system complexity because the entire coating delivery subsystem can be replaced as a single unit rather than managing multiple separate components.
Solution Approach 2:
The cartridge contains its own recirculation loop with a first pump that continuously circulates coating within the cartridge, and its own filter and debubbling system. This self-service capability means the cartridge maintains its own coating quality without requiring external system intervention, simplifying the overall system architecture.
3Loss of substance
If coating is continuously recirculated through a recirculation loop, then coating consistency is maintained and waste is reduced, but the system requires additional pumps and piping increasing complexity
Solution Approach 1:
The recirculation system is segmented into the cartridge's internal first pump and recirculation loop, separate from the main system's second pump for delivery. This segmentation allows the recirculation function to be contained within the replaceable cartridge, reducing the complexity of the permanent system while maintaining continuous recirculation benefits.
Solution Approach 2:
The first pump in the cartridge continuously recirculates the coating through the recirculation loop, maintaining constant motion of the coating material. This continuous action prevents coating settlement, maintains consistency, and reduces waste by ensuring the coating is always ready for delivery without needing to be replenished or reconditioned.
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
Enables flexible and efficient application of multiple coatings on optical articles, reducing waste and operational complexity while maintaining coating consistency.
Implementation Method 1
a first pump in fluid communication with the recirculation loop. The first pump is configured for recirculating the coating from the reservoir through the recirculation loop
Implementation Method 2
a second pump in fluid communication with the recirculation loop. The second pump is configured to selectively aspirate the coating from the recirculation loop and deliver the coating to a coating device
Data Source
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AI summary
A replaceable cartridge for a coating system includes a reservoir configured for containing a volume of a coating and a recirculation loop having an inlet and an outlet in fluid communication with the reservoir. The cartridge further includes a first pump in fluid communication with the recirculation loop. The first pump is configured for recirculating the coating from the reservoir through the recirculation loop. The cartridge further includes a second pump in fluid communication with the recirculation loop, the second pump being configured to selectively aspirate the coating from the recirculation loop and deliver the coating to a coating device.