Rotary Coating Apparatus with Dynamic Fluid Control
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Solution Overview
Problem
Existing coating methods for plastic bottles, such as PET, face challenges including insufficient gas impermeability, short shelf life, high costs, and inflexible process sequences, with issues like parallel pump connections reducing efficiency and rotatable distributors being prone to faults and inflexible.
Innovation Solution
A flexible apparatus with multiple treatment devices and a fluid control system using valve arrangements allows independent control of fluid supply, enabling variable process sequences, high throughput, and efficient coating with two-layer systems for improved bonding and barrier properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large number of treatment stations are arranged on the conveyor carousel to achieve high throughput, then productivity is improved, but the risk of multiple stations being simultaneously connected to the same pressure source increases, causing system conflicts and reducing reliability
Solution Approach 1:
The patent applies dynamics by making the pressure source connections dynamic rather than fixed. The connection between treatment stations and pressure sources changes over time based on the rotational position of the carousel and the process phase of each station. This dynamic reconfiguration allows the system to maintain high throughput with many stations while preventing simultaneous conflicts by ensuring each pressure source connects to at most one station at any given moment.
Solution Approach 2:
The patent implements preliminary action by pre-planning and coordinating the connection timing of each treatment station to pressure sources. The control system anticipates potential conflicts and schedules connections in advance based on the rotational positions and process phases, ensuring that no two stations attempt to connect to the same pressure source simultaneously, thus maintaining system reliability.
2Device complexity
If stationary pumps are used with long paths from stations to pump, then device complexity is reduced, but pump power is reduced due to long paths, affecting coating quality
Solution Approach 1:
The patent resolves this contradiction by making the pump arrangement dynamic. Instead of fixed stationary pumps with long connection paths, the system uses rotating distributors that move with the carousel, maintaining short connection paths between pumps and treatment stations throughout the rotation. This dynamic approach preserves pump power while managing system complexity through coordinated motion.
Solution Approach 2:
The rotating distributor acts as an intermediary between the stationary pumps and the moving treatment stations. It transfers fluid under pressure while rotating synchronously with the carousel, enabling short connection paths without requiring pumps to be mounted on the rotating carousel itself, thus balancing power requirements and device complexity.
3Device complexity
If a rotatable distributor with fixed opening arrangement is used to connect pumps to stations, then device complexity is managed, but the design becomes inflexible and difficult to seal, increasing maintenance requirements
Solution Approach 1:
The patent overcomes the inflexibility of fixed opening arrangements by implementing dynamic control of the rotating distributor. The opening positions and timing are adjustable based on the rotational speed and process requirements, allowing the system to adapt to different coating processes and sequence variations while maintaining manageable device complexity through a single rotating component design.
4Productivity
If parallel connection of multiple pumps is implemented, then productivity is improved through simultaneous operation, but multiple tube routing is required, increasing device complexity
Solution Approach 1:
The patent applies merging by combining multiple tube routing functions into the rotating distributor component. Instead of separate fixed routing for each pump-station connection, the rotating distributor integrates all connections into a single rotating assembly that dynamically establishes the required pathways, enabling parallel pump operation while managing overall system complexity.
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
The apparatus achieves reliable, high-throughput coating with improved shelf life and reduced costs, ensuring excellent quality and flexibility in process parameters, while minimizing the risk of layer flaking and color issues.
Implementation Method 1
a fluid supply apparatus, which supplies the treatment device with at least one process fluid for the coating
Implementation Method 2
a fluid control device, in particular a first valve arrangement having a plurality of valves, the supply of fluid to the treatment devices being controllable by means of the first valve arrangement
Data Source
AI summary
The invention relates to an apparatus and a method for the coating of hollow bodies, in particular for the internal coating of plastic drinks bottles by means of a PICVD. It is an object of the invention to ensure a flexible process sequence, a high throughput, an improved supply of fluid and a high-quality coating. The invention in particular proposes a rotary apparatus which comprises a treatment device with double reactors for receiving in each case at least one workpiece, a fluid supply apparatus and at least one fluid control device, which can be used to control the supply of fluid to the treatment device. It is preferable for the vacuum pumps to be arranged on the rotor such that they rotate therewith.