Vacuum Coating Device Flow Distribution Box for Uniform Metal Steam
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Solution Overview
Problem
Existing vacuum coating technologies face challenges in achieving uniform coating thickness and consistency due to non-uniform distribution of metal steam from the nozzles, leading to uneven coatings on steel plates.
Innovation Solution
A vacuum coating device is designed with a crucible, an induction heater, a flow distribution box, a pressure stabilizing plate with a multi-hole structure, and a flow suppression plate. This configuration redirects and redistributes the metal steam to ensure even distribution across the steel plate, forming a uniform jet stream and coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional nozzle structures are used for metal steam distribution, then the coating process can be implemented, but the metal steam distribution is non-uniform leading to inconsistent coating thickness
Solution Approach 1:
The flow distribution box is divided into multiple functional zones: a metal steam inlet zone, a flow distribution zone with multiple nozzles arranged in specific patterns, and a flow regulation zone. This segmentation allows each zone to perform its specific function optimally, ensuring uniform metal steam distribution across the coating surface while maintaining manageable structural complexity
Solution Approach 2:
Different regions of the flow distribution box are designed with locally optimized characteristics. The nozzles are positioned and sized differently in various zones to account for variations in metal steam flow patterns and pressure distributions. This local quality approach ensures that each area receives the appropriate amount of metal steam for uniform coating thickness
2Manufacturing precision
If simple nozzle arrangements are used, then the device structure remains simple, but the metal steam cannot be evenly distributed across the steel plate
Solution Approach 1:
The flow distribution box serves as an intermediary device between the metal steam source and the coating surface. It contains multiple nozzles that act as intermediate distribution points, breaking down the metal steam flow into smaller, more uniformly distributed streams. This intermediary structure transforms the concentrated metal steam flow into an evenly distributed pattern across the steel plate
Solution Approach 2:
The flow distribution system transitions the metal steam distribution from a one-dimensional point source to a two-dimensional distributed pattern across the coating surface. Multiple nozzles arranged in specific geometric patterns create a planar distribution field, ensuring coverage across the entire steel plate width and length for uniform coating
3Productivity
If high-speed metal steam spray is used for efficient coating, then productivity increases, but coating uniformity decreases due to non-uniform steam distribution
Solution Approach 1:
The flow distribution box maintains continuous and steady metal steam flow to all nozzles through its internal flow paths and pressure equalization features. This continuous supply ensures that each nozzle delivers metal steam at consistent rates without interruption or fluctuation, enabling high-speed coating while maintaining uniform thickness across the entire surface
Solution Approach 2:
The system controls and optimizes parameters such as nozzle positioning, nozzle diameter, metal steam pressure, and flow velocity to achieve the desired balance between coating speed and uniformity. By carefully adjusting these parameters, the system maintains high productivity while ensuring consistent coating thickness through uniform metal steam distribution
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 on steel plates by ensuring even distribution of metal steam, improving the quality and consistency of the vacuum-coated steel plates.
Implementation Method 1
heating the metal to be coated under vacuum to deposit the metal in a gaseous manner
Implementation Method 2
an induction heater provided on the periphery of the crucible
Implementation Method 3
said flow distribution box is provided inside with a horizontal pressure stabilizing plate... forming a uniform jet stream
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
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 flow distribution box is provided inside with a horizontal pressure stabilizing plate, said flow distribution box is connected on the top with a nozzle, said steam pipe is provided with a pressure regulating valve, and said pressure stabilizing plate has a multi-hole structure. The lower surface of said pressure stabilizing plate is connected to a horizontal flow suppression plate, and a space is formed between the side of said flow suppression plate and the inner wall of said flow distribution box. A jet moderating zone is formed between the joint where said flow distribution box and said steam pipe are connected and the lower surface of said pressure stabilizing plate, and a jet accelerating zone is formed between the upper surface of said pressure stabilizing plate and the joint where said flow distribution box and said nozzle are connected. When the high-temperature steam reaches the low-temperature steel plate, a uniform coating can be formed on the steel plate surface.