Viscous Vapor Flow for Uniform Coating
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Solution Overview
Problem
Existing methods for all-round coating of objects in a vacuum chamber are complex and costly, often requiring intricate mechanical arrangements and equipment to rotate or move workpieces to ensure uniform coating, which is inefficient for larger objects or batches.
Innovation Solution
A method that utilizes a viscous flow within the process chamber by vaporizing a material with a vapor pressure greater than 1 Pa at 550 K to 670 K, distributing and deflecting the material vapor/mist with active or passive means to create a directed flow around objects on all sides, eliminating the need for complex mechanical movements of the objects or source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex mechanical arrangements are used to rotate or move workpieces for uniform coating, then coating uniformity is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces mechanical rotation systems with a gas flow-based coating distribution system. A coating material source releases material that is carried by gas flow through distribution channels to multiple coating heads, which then deposit coating on workpieces without requiring mechanical movement of the workpieces or coating heads.
Solution Approach 2:
The patent introduces gas flow as an intermediary medium to transport coating material from the source to the workpieces. The gas acts as a carrier that distributes the coating material uniformly across multiple workpieces simultaneously, eliminating the need for direct mechanical contact or movement.
2Manufacturing precision
If workpieces are rotated or moved for all-round coating, then coating coverage is improved, but productivity decreases due to complex equipment
Solution Approach 1:
The patent divides the coating system into multiple independent coating heads, each serving specific workpieces. The coating material is segmented and distributed through separate channels to different locations, allowing simultaneous coating of multiple workpieces in parallel without requiring rotation or sequential processing.
Solution Approach 2:
The patent transitions from one-dimensional sequential coating (requiring rotation) to three-dimensional parallel coating. Multiple coating heads are arranged in space to coat multiple workpieces simultaneously at different positions, adding spatial dimensionality to the coating process and dramatically improving productivity.
3Manufacturing precision
If vacuum coating is used for all-round coverage, then coating quality is improved, but equipment cost and complexity increase
Solution Approach 1:
The patent employs passive distribution channels that rely on natural gas flow and pressure differential to transport coating material. The system uses the inherent properties of gas flow and pressure to distribute material uniformly without requiring active pumping or complex control mechanisms at each coating head.
Solution Approach 2:
The patent creates a universal coating system where a single material source serves multiple workpieces through a network of distribution channels. The same gas flow mechanism and coating material source can coat different types and numbers of workpieces by adjusting flow parameters, providing multi-functionality without requiring separate coating equipment for each workpiece.
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
Enables uniform coating of objects on all sides without the need for complex equipment or movement, improving the utilization of vapor deposition devices and reducing costs by allowing coating of larger objects and batches without line-of-sight limitations.
Implementation Method 1
a material source (28) which vaporizes material (32)
Implementation Method 2
a passive means (36) for distributing and deflecting the material vapor and/or mist cloud (34)
Implementation Method 3
an active means (46) for distributing and deflecting the material vapor and/or mist cloud (34)
Implementation Method 4
the material vapor flowing around the objects (20) on all sides condenses as an uniform layer on the objects
Implementation Method 5
a vacuum pump (22) for creating and maintaining a vacuum within the process chamber (12)
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
In the application of a thin all-round coating to e.g. spectacle lenses in a rack, coating material (28) is converted from its solid state into atomized particles (34) by an electrically heated crucible within a gas chamber. The atomized particles circulate as a viscous flow within the partially evacuated chamber. Circulation of the atomized particles is promoted by active or passive means. Also claimed is a commensurate coating assembly.