Ultrasonic Diffuser Coating Reduces Material Waste
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Solution Overview
Problem
Existing diffuser coating processes are inefficient, resulting in high material waste and non-uniform coatings due to high pressure air atomization, which also require costly and labor-intensive manual handling and high-capacity air circulation systems.
Innovation Solution
The use of an ultrasonic vibrating device to atomize coating material, combined with a low-pressure air flow to guide particles onto a substrate surface, reducing waste and improving coating uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If high pressure air atomization is used to deposit coating particles, then coating coverage is achieved, but material waste increases to 80-90 percent
Solution Approach 1:
The patent replaces the high pressure air mechanical atomization system with an ultrasonic vibration-based atomization system. The ultrasonic transducer vibrates at high frequency to atomize the coating material into fine particles, eliminating the need for high pressure air and significantly reducing material waste from 80-90% to much lower levels.
Solution Approach 2:
The patent changes the operating parameters from high pressure (240 p.s.i.) to low pressure (less than 80 p.s.i., preferably less than 50 p.s.i.), and introduces ultrasonic vibration frequency as a new controlling parameter for atomization. This parameter transformation enables controlled particle generation with minimal material waste.
2Manufacturing precision
If high pressure air compressor is used to atomize coating material, then particle cloud is generated, but coating uniformity deteriorates due to uncontrolled spray
Solution Approach 1:
The patent replaces the complex high pressure air compression and circulation system with a simple ultrasonic vibration system. The ultrasonic transducer directly atomizes the coating material without requiring high pressure air compressors, circulation fans, or filtration systems, thereby achieving uniform coating with simplified equipment.
3Object-affected harmful factors
If high flow rate air circulation system is used to remove contaminated air, then particle removal is achieved, but system cost and energy consumption increase
Solution Approach 1:
The patent extracts and removes the high flow rate air circulation system entirely from the coating process. By using ultrasonic atomization with low pressure air, the system generates minimal airborne particles that do not require high volume air circulation for removal, thereby eliminating the energy-consuming HVAC system.
4Ease of operation
If manual substrate handling is used in coating process, then substrate positioning is achieved, but labor intensity and processing time increase
Solution Approach 1:
The patent enables continuous substrate processing by maintaining a stable, controlled particle stream from the ultrasonic atomization system. Substrates can be continuously fed through the coating zone without manual intervention, as the low pressure particle cloud provides consistent coating coverage, thereby increasing productivity and eliminating manual labor.
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 method significantly reduces waste and labor costs by efficiently depositing particles with a high degree of uniformity, eliminating the need for high-pressure air systems and manual handling, while allowing for continuous substrate processing.
Implementation Method 1
The present invention provides a process or method or system for applying or depositing or establishing a diffuser coating and/or a protective coating onto a substrate surface. The system atomizes or vaporizes the liquid coating material via an ultrasonic vibrating device
Implementation Method 2
A low pressure air flow, preferably an air flow of less than about 80 p.s.i., more preferably lower than about 50 p.s.i., and most preferably at or lower than about 40 p.s.i. or thereabouts, is provided to guide at least some of the airborne particles onto the substrate surface
Data Source
AI summary
A system for coating a substrate surface with a diffuser coating includes an ultrasonic vibrating device, a supply device and a low pressure air source. The supply device supplies a liquid coating material or precursor solution to the ultrasonic vibrating device. The ultrasonic vibrating device is operable to vibrate to atomize the coating material and to discharge airborne particles at a discharge end of the ultrasonic vibrating device. The low pressure air source generates low pressure air flow generally proximate to the discharge end to guide at least some of the airborne particles onto the substrate surface. The ultrasonic vibrating device may be at a coating chamber and the substrate may be positionable within the coating chamber. A conveyor may be operable to convey substrates through the coating chamber, whereby the coating particles are guided onto the substrate surface as the substrate moves through the coating chamber.