Resin Container Coating Device with Power Switching
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Solution Overview
Problem
The challenge is to uniformly form high-quality films with predetermined barrier performance on resin containers while minimizing the size and cost of the high-frequency power source required for collective film formation, as insufficient power leads to quality dispersion and increased costs.
Innovation Solution
A resin container coating device with multiple independent chambers and internal electrodes, a gas supply unit, and an electric power switching system that alternates high-frequency power supply between chambers, allowing for sequential film formation and efficient gas distribution, reducing the need for a large high-frequency power source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large high frequency power source is supplied to form films on multiple resin containers simultaneously, then uniform film quality with predetermined barrier performance is achieved, but device cost increases
Solution Approach 1:
The treatment chamber is divided into multiple independent treatment regions, each capable of receiving high frequency power independently. This allows sequential activation of different regions, enabling multiple containers to be treated in batches without requiring all regions to operate simultaneously, thus reducing the total power source size while maintaining film quality uniformity in each batch
Solution Approach 2:
The high frequency power is supplied periodically to different treatment regions in a sequential manner. By activating one treatment region at a time and then switching to the next region, the system achieves periodic action that allows multiple containers to be processed through successive batches, reducing the peak power requirement while maintaining consistent film quality across all containers
2Productivity
If a large high frequency power source is supplied to form films on multiple resin containers simultaneously, then production efficiency is improved, but device cost increases
Solution Approach 1:
The chamber is segmented into multiple treatment regions with multiple internal electrodes, allowing batches of containers to be processed simultaneously in different regions. By sequentially activating these regions, the system achieves high throughput without requiring a single large power source, thus improving productivity while controlling device cost
Solution Approach 2:
The system uses periodic activation of different treatment regions to process multiple batches of containers. While one region is being treated, another region can be prepared or is being cooled down, creating a periodic workflow that maintains high production efficiency without requiring all regions to operate at full power simultaneously
3Reliability
If high frequency power is supplied to multiple chambers simultaneously, then film formation is achieved, but power consumption increases
Solution Approach 1:
The high frequency power is supplied in periodic cycles to different treatment regions rather than continuously to all regions simultaneously. Each region receives power in alternating sequences, ensuring reliable film formation in each batch while significantly reducing the total power consumption compared to simultaneous operation of all regions
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 enables efficient sequential plasma film formation across multiple resin containers, suppressing the required high-frequency power and improving production efficiency by allowing common pretreatments to be performed simultaneously, while optimizing power distribution for uniform film quality.
Implementation Method 1
a film forming process by the generation of plasma can be sequentially carried out to the plurality of chambers
Implementation Method 2
a high frequency power source for supplying a high frequency electric power to the plurality of chambers
Implementation Method 3
a plasma CVD film-forming technique
Data Source
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AI summary
An object of the present invention is to suppress enlargement in a high frequency power source and improve production efficiency. A resin container coating device of the present invention includes a plurality of chambers (40A, 40B, 40C, 40D) storing a plurality of resin containers (B) respectively in independent states, a plurality of internal electrodes (50) in which gas conductive parts (51) for conducting a source gas are formed to inner peripheral parts thereof and which are respectively inserted inside the plurality of resin containers (B) stored in the chambers, a gas supply unit (70) for supplying the source gas to the plurality of chambers (40A, 40B, 40C, 40D), a high frequency power source (80) for supplying a high frequency electric power to the plurality of chambers (40A, 40B, 40C, 40D), and an electric power switching part (85) capable of switching a supply designation of the high frequency electric power, which is supplied from the high frequency power source (80), from first and second chambers (40A, 40B) forming a first unit (U1) to third and fourth chambers (40C, 40D) forming a second unit (U2).