Vacuum Coating Device Deflector Nozzle Uniformity
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Solution Overview
Problem
Existing vacuum coating technologies struggle to achieve uniform coatings with consistent thickness on steel plates, leading to low yield and increased production costs due to non-uniform coating distribution.
Innovation Solution
A vacuum coating device with a crucible, induction heater, flow distribution box, pressure regulating valve, and a deflector arranged above the nozzle to concentrate the metal steam onto the steel plate, ensuring uniform coating distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional nozzle arrangements are used, then the device structure is simple, but the coating thickness is non-uniform
Solution Approach 1:
The flow distribution box is divided into multiple chambers (first flow distribution chamber, second flow distribution chamber, third flow distribution chamber) with separate nozzle groups for different regions. This segmentation allows independent control of metal steam flow to different areas of the steel plate, enabling uniform coating thickness across the entire surface while maintaining manageable structural complexity through modular design
Solution Approach 2:
Different nozzle groups are positioned at different heights and angles to deliver metal steam to different regions of the steel plate. The first nozzle group targets the first region, the second nozzle group targets the second region, and the third nozzle group targets the third region. This local quality approach ensures that each region receives appropriate metal steam flow for uniform coating, resolving the contradiction between coating uniformity and structural simplicity
2Productivity
If metal steam is sprayed without flow distribution control, then the device operation is simple, but the coating yield is low
Solution Approach 1:
The flow distribution box pre-distributes metal steam into different chambers and directs it through multiple nozzle groups before the steam reaches the steel plate. This preliminary action ensures that metal steam is already properly distributed and directed, maximizing coating yield by ensuring comprehensive coverage of the steel plate surface while automating the distribution process to avoid complex manual operation
Solution Approach 2:
The flow distribution box acts as an intermediary device between the metal steam source and the steel plate. It receives metal steam from the crucible, distributes it through multiple chambers and nozzle groups, and delivers it uniformly to different regions of the steel plate. This intermediary structure improves coating yield by ensuring proper steam distribution while simplifying operation through automated flow management
3Manufacturing precision
If the nozzle sprays metal steam directly to the steel plate, then the device structure is simple, but the coating thickness consistency is poor
Solution Approach 1:
The flow distribution box is segmented into multiple chambers (first, second, and third flow distribution chambers) with separate nozzle groups for different regions. This segmentation allows independent optimization of metal steam delivery to each region, achieving consistent coating thickness across the entire steel plate while maintaining structural manageability through modular organization
Solution Approach 2:
The invention introduces vertical dimensionality by positioning nozzle groups at different heights (first nozzle group at first height, second nozzle group at second height, third nozzle group at third height). This multi-level arrangement allows metal steam to reach different regions of the steel plate from different vertical positions, improving thickness consistency while organizing the complex flow distribution structure in a systematic three-dimensional configuration
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 device achieves a uniform coating with consistent thickness, significantly improving the yield of the coating to over 90% and reducing production costs by minimizing the need for cutting off unevenly coated parts.
Implementation Method 1
a crucible (13), an induction heater (15) provided on the periphery of the crucible (13)... the nozzle (20) sprays the metal steam (22) to the steel plate (100)
Implementation Method 2
an induction heater (15) provided on the periphery of the crucible (13)
Implementation Method 3
said flow distribution box (17) is provided inside with a horizontal pressure stabilizing plate (19)
Implementation Method 4
Physical vapor deposition (PVD) refers to a process technology of heating the metal to be coated under vacuum to deposit the metal in a gaseous manner on a base material to form a coating
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention discloses a vacuum coating device, comprising: a crucible, an induction heater provided on the periphery of the crucible, a flow distribution box connected to the top of said crucible via a steam pipe, wherein said steam pipe is provided with a pressure regulating valve, said flow distribution box is provided inside with a horizontal pressure stabilizing plate, said flow distribution box is connected on the top with a nozzle, and a deflector being arranged above said nozzle along the emitting direction of the steam. Wherein a distance Da from nozzle outlet to steel plate is 10~200 mm, a height Db of said deflector is 10~199mm; a distance Dc from top of said deflector to steel plate is 1∼190mm; an angle Dd between said deflector and said nozzle outlet is 60°∼135°. The vacuum coating device in the present invention can improve the yield of the coating, and also can form a uniform coating with consistent thickness.