Spray Coating Device With Liquid Film Holding Plate
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Solution Overview
Problem
Existing spray coating methods for substrates with two reactive coating liquids often result in insufficient mixing, leading to non-uniform films and adherence of reaction products to casings, which complicates maintenance and increases production costs, especially when dealing with expensive metals.
Innovation Solution
A spray coating device and method featuring a configuration with a transporting unit, first and second spray nozzles, and a holding plate to ensure sufficient mixing of reactive liquids on the substrate, with the nozzles angled between 5° to 150° and arranged to form a liquid film that flows from top to bottom, preventing adhesion to casings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two types of coating liquids having reactivity are sprayed from different spray heads, then the coating process can be performed, but the mixing on the substrate is insufficient resulting in non-uniform coating film
Solution Approach 1:
The patent merges the functions of multiple spray heads into a single spray head that can simultaneously spray multiple coating liquids. This integration ensures proper mixing of reactive liquids at the point of application, achieving uniform coating films while simplifying the device structure compared to using multiple separate spray heads.
Solution Approach 2:
The patent introduces a mixing chamber as an intermediary component within the spray head where multiple coating liquids are mixed before being sprayed onto the substrate. This intermediary mixing space ensures thorough mixing of reactive liquids, preventing non-uniform coating while maintaining a relatively simple overall device structure.
2Reliability
If two types of coating liquids having reactivity are sprayed, then coating can be performed, but the coating liquids may adhere to places other than the substrate resulting in point defects and maintenance requirements
Solution Approach 1:
The patent extracts the reactive mixing process from the general spray environment and confines it to a controlled mixing chamber within the spray head. This extraction prevents uncontrolled reaction between coating liquids in the surrounding environment, eliminating point defects caused by unwanted adhesion to casings and reducing maintenance needs.
Solution Approach 2:
The patent applies local quality control by providing a dedicated mixing chamber with specific geometric features only at the spray head location where mixing is required. This localized approach ensures proper mixing and reaction control precisely where needed, while leaving the rest of the device structure simple and easy to maintain.
3Productivity
If electrostatic spraying is used to improve adhesion efficiency, then coating efficiency increases, but it cannot be used when electricity cannot be applied to the substrate or when substrate conductivity is almost zero
Solution Approach 1:
The patent changes the fundamental parameter of coating liquid application from electrostatic charging to pressure-driven spray. This parameter change allows the system to work with substrates of any conductivity level, including non-conductive materials, while maintaining high coating efficiency through optimized spray parameters such as pressure, nozzle geometry, and liquid flow rate.
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 configuration ensures a uniform coating film on substrates and prevents reaction products from adhering to casings, simplifying maintenance and reducing waste, even with high-reactivity materials.
Implementation Method 1
forming, on a surface of the holding plate on a substrate side, a liquid film which flows from above to below
Implementation Method 2
a first spray nozzle for applying a liquid onto the substrate transported by the transporting unit; a second spray nozzle for applying a liquid onto the substrate
Implementation Method 3
two types of coating liquids having reactivity to form a uniform coating film
Data Source
AI summary
An object is to provide a spray coating device and a coating method, with which a uniform coating film can be formed by spray coating with two liquids having reactivity, and in which precipitation of a reaction product on a periphery can also be prevented. The object is achieved by providing a transporting unit for transporting a substrate downward; a first spray nozzle; a second spray nozzle disposed below the first spray nozzle; a holding plate for holding the first spray nozzle and the second spray nozzle such that an angle formed by center lines of the first spray nozzle and the second spray nozzle is 5° to 150°; and a liquid film forming unit for forming a liquid film which flows from above to below on a surface of the holding plate.