Vacuum Coating Device Steam Distribution for Strip Steel
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Solution Overview
Problem
Existing vacuum coating technologies face challenges in achieving uniform coating thickness and adhesion on strip steel, particularly at high production speeds, due to non-uniform nozzle designs and increased pipe diameters, leading to uneven coatings and poor adhesion between coating interfaces.
Innovation Solution
A vacuum coating device with a crucible, induction heater, and a flow distribution system including a pressure regulating valve, diverter valve, and a pressure stabilizing plate, where sub-nozzles are arranged in parallel with specific spacing and outlet types to ensure uniform steam distribution, achieving a spray flow that continuously covers the steel strip with a consistent coating thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pipe diameter is increased to meet high delivery speed requirements, then the coating speed can be increased, but the coating uniformity deteriorates due to non-uniform steam distribution
Solution Approach 1:
The patent divides the single large-diameter pipe into multiple smaller sub-pipes (e.g., 3-5 sub-pipes). Each sub-pipe delivers steam to a corresponding sub-nozzle, ensuring that even at high delivery speeds, the steam distribution remains uniform across the coating width. This segmentation resolves the contradiction by maintaining coating uniformity while enabling high-speed operation.
Solution Approach 2:
The patent transitions from a single-dimensional (single pipe) steam delivery system to a multi-dimensional (multiple sub-pipes arranged in array) system. The sub-pipes are positioned at different locations to ensure comprehensive and uniform steam distribution across the entire coating area, thereby maintaining coating uniformity at high speeds.
2Quantity of substance
If multiple deposition operations are performed to achieve required coating thickness, then the coating thickness can be increased, but the adhesion between coating interfaces deteriorates
Solution Approach 1:
The patent enables continuous coating deposition by providing sufficient steam flow rate through the multi-sub-pipe system. The steam delivery capacity is designed to achieve the required coating thickness in a single continuous pass, eliminating the need for multiple deposition operations and thus preventing adhesion problems at coating interfaces.
3Productivity
If the nozzle opening degree is increased to meet galvanizing flow rate requirements, then the coating speed can be increased, but the coating uniformity deteriorates
Solution Approach 1:
Instead of using a single large-opening nozzle, the patent employs multiple sub-nozzles with smaller individual openings. Each sub-nozzle is positioned to cover a specific zone, and the collective output of all sub-nozzles meets the required galvanizing flow rate. This segmentation maintains coating uniformity while achieving high productivity.
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 the steel strip with improved adhesion by optimizing the distribution of steam through sub-nozzles, allowing for efficient coating at high speeds without the need for multiple deposition operations, thus enhancing coating uniformity and reducing investment and operational complexity.
Implementation Method 1
an induction heater is arranged on the outer side of the crucible
Implementation Method 2
heating the metal to be coated under vacuum conditions to deposit the metal in a gaseous manner
Implementation Method 3
Physical vapor deposition (PVD) refers to a process technology of heating the metal to be coated under vacuum conditions to deposit the metal in a gaseous manner on a base material to form a coating
Data Source
AI summary
Provided is a vacuum coating device, comprising a crucible (13), an induction heater (15) arranged on the outer side of the crucible (13); a flow distribution box connected to the top of the crucible (13) through a steam pipeline (16); a pressure regulating valve (18) and a diverter valve (19) sequentially arranged in a direction in which the steam pipeline (16) is in communication with the flow distribution box; a horizontal pressure stabilizing plate (20) arranged in the flow distribution box, a plurality of sub-nozzles (21) connected to the top of the flow distribution box; wherein a plurality of air flow distribution chambers are arranged in the diverter valve (19); a ratio of a total area of the air flow distribution chambers (Sdistribution) to an area of the steam pipeline (16) in the radial direction (Spipeline) is greater than or equal to 0.1, i.e.: Sdiversion/Spipelineā„0.1. According to the device, a uniform spray flow can be formed, a uniform coating (23) is formed on the surface of a steel plate (100) when high temperature steam is in contact with a low temperature steel plate, the spray flow formed by the sub-nozzles (21) arranged at the rear portion continuously covers the deposited metal layer that has been formed, so as to achieve efficient coating of strip steel under vacuum conditions.