Wire Coating Device Uniform Thickness Control
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Solution Overview
Problem
The manufacture of non-metallic filaments with fiberglass wire impregnated with thermoset resin coated with resorcinol formaldehyde latex (RFL) glue faces challenges due to the smooth surface of the CVR yarn not absorbing the glue, non-uniformity in glue thickness, and environmental pollution from existing coating processes.
Innovation Solution
A coating device with a housing, die body, and calibrated die channel that allows the yarn to pass through a deposit space where the coating material is applied, with excess material evacuated, ensuring uniform coating and minimizing environmental exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the coating material is supplied in large quantity to ensure adequate coating, then the coating coverage is improved, but the uniformity of coating thickness deteriorates due to difficulty in controlling distribution
Solution Approach 1:
The die body introduces localized control structures (calibrated die channel, containment walls with through orifices) that create different functional zones within the coating apparatus. The calibrated die channel provides precise geometric control for uniform coating thickness, while the containment walls with orifices allow localized material distribution. This local differentiation enables both adequate coating quantity and uniform thickness distribution.
Solution Approach 2:
The patent employs a calibrated die channel with specific geometric parameters (cross-sectional area, length, orientation) that control the coating material flow and distribution. By adjusting the die channel dimensions and configuration, the system optimizes the balance between material quantity supplied and uniformity of coating thickness, transforming the coating process through precise parameter control.
2Device complexity
If the coating process is conducted in open air to simplify the device structure, then the device complexity is reduced, but the coating quality deteriorates due to physical and chemical transformations of the coating material
Solution Approach 1:
The patent introduces a coated wire receiver as an intermediary component that collects the coated wire immediately after it exits the die channel. This receiver acts as a buffer between the controlled coating environment and the external atmosphere, preventing premature exposure of the coating material to air that would cause degradation. The receiver maintains coating quality while allowing the overall device to remain relatively simple.
3Ease of operation
If the coating material is exposed to air during the coating process to simplify material supply, then the ease of operation is improved, but the coating material undergoes degradation transformations
Solution Approach 1:
The patent extracts the coating material from direct air exposure by confining it within the sealed chamber and die body structure during the critical coating application phase. The calibrated die channel and containment walls create a controlled environment that isolates the coating material from atmospheric conditions that would cause degradation, while still allowing for practical material supply operations.
4Reliability
If a sealed chamber is used to protect the coating material from air exposure, then the coating material stability is improved, but the device complexity increases
Solution Approach 1:
The patent segments the sealed chamber into distinct functional zones: the chamber body for material containment, the die body with calibrated channel for precise coating application, and the coated wire receiver for collection. This segmentation allows each component to perform its specific function efficiently, reducing overall system complexity while maintaining the protective sealed environment necessary for coating material stability.
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 solution achieves uniform and efficient application of the coating material, reducing environmental impact by keeping the coating process enclosed and allowing for precise calibration of the coating thickness, thereby improving the manufacturing process of non-metallic filaments.
Implementation Method 1
depositing coating material on the wire as it passes through said deposition space
Implementation Method 2
discharging excess potting material from said deposit space and said die gauge channel through said lower exit port of said chamber
Data Source
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AI summary
The invention relates to a device for coating a wire with a coating material, including: a housing (2) which includes a holder (4) and a cover (5) mounted on the holder, defining a chamber (6), and a die body (18) installed in said chamber, between the holder and the cover. An inlet passage (41) and an outlet passage (42) are arranged between the holder and the cover, the die body comprising a lower part and an upper part (18a, 18b), a sized die channel (35) being arranged therebetween, said inlet and outlet passages and said sized die channel being aligned such that the wire (2) can pass longitudinally therethrough. The device includes a duct (43) for transporting the coating product, having a lower outlet end located near the wire (2), between the upstream through-passage and the die channel.