CN101980794A - 使用喷涂方法来涂覆物品的方法和装置 - Google Patents
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Abstract
本发明涉及一种使用喷涂方法来涂覆物品的方法和装置。可通过将流体涂覆前体材料雾化成平均直径在0.5至5微米的液滴而产生涂层。以超过临界冲击速度的速度将液滴引入到待涂覆的物品上。可通过控制喷雾腔室中流体前体材料溶剂的浓度来控制液滴的蒸发。
Description
技术领域
本发明涉及使用喷涂(spray-coating)方法来涂覆物品。用根据本发明的方法和装置，能有利地通过将流体涂覆前体材料雾化成平均直径范围在0.5至5微米的液滴并以超过临界冲击速度的速度将液滴引入到待涂覆物品上来产生涂层。根据本发明，可通过控制喷雾腔室中流体前体材料溶剂的浓度来控制液滴蒸发。
背景技术
就此而言，喷涂是一种用于施加涂层的已知方法。喷涂的典型实例为(例如)纸的喷漆和颜料涂覆。
Metso Paper公司的2000年7月19日的专利公告FI 111478 B公开了一种用于纸张涂覆的喷涂方法，在该方法中，利用喷嘴将涂覆混合物施加到纸幅表面上，涂覆混合物在喷涂到纸幅上之前在喷嘴中雾化成小液滴。该专利公告公开了下面这样的方法：在封闭罩内执行喷涂，可将封闭罩的内壁制成可冷却的，且罩的温度和湿度可被设置为所需值。该专利公告并未提及流体滴大小和喷雾速度。
Takashi Yonehara等人的1987年4月14日的专利公告US 4,656,963公开了一种在物体表面上形成极薄膜的方法。在该方法中，从前体材料产生气溶胶且将气溶胶引入到待涂覆的基片表面上，且在溶剂蒸发之后，在表面上形成膜。该专利公告公开了通过超声生成粒度范围在1.5至10微米的气溶胶颗粒。该专利公告并未描述如何通过冲击将气溶胶颗粒引入到待涂覆的基片表面上。
Glaverbel的1988年3月1日的专利公告US 4,728,353公开了一种用于在热玻璃基片上形成热解金属化合物涂层的装置。对于该装置的操作，必须通过向玻璃基片面供应预热气体来控制在玻璃基片面紧邻处的气体气氛，预热气体在玻璃基片面附近形成保护性气氛。保护性气氛使得能防止周围空气进入到涂覆区域。该专利公告公开了预热气体为预热空气，表示涂覆反应发生于富含氧的气氛中。通过喷雾来进给涂覆前体材料公开于该公告中，但并未公开雾滴直径。因为在1988年，喷雾器不够先进以产生小液滴，所以在当时对于本领域技术人员显然雾滴直径在数十微米的范围。美国的1989年的Arthur H.Lefebvre的公告(Atomization and Sprays，Taylor&Francis)公开了一组不同喷雾器。在该专利公告中频繁使用的词语“薄雾”是指大约100微米直径的液滴(在该公告的第80页)且在所述公告中公开的压力与空气分散喷雾器的液滴大小分布(尤其是第201-273页)从未示出小于10微米的液滴，平均直径通常在30至80微米的范围。在该公告中提到这种液滴蒸发能在10秒周期内进行，只要空气温度为数百度，如在该公告中所述。但是，空气加热使得溶液较为昂贵，特别是当使用大量空气时，如在该公告中所述。
Xingwu Wang的1996年6月30日的专利公告US 5,540,959，公开了一种使用雾粒来制备涂覆基片的方法。在该方法中，产生小液滴，利用射频能量来加热小液滴以使液滴汽化，之后，将蒸汽沉积到基片上。所述公告并未提及流体滴撞击、碰撞或冲击到基片表面上。
James J.Sun等人的2002年8月1日的专利申请公开US 2002/0100416 A1公开了一种使用气溶胶来涂覆基片的方法，其中使用冲击板从流中移除大于特定液滴大小的液滴。所述公告并未提供使用冲击将液滴沉积到基片上的描述。
1999年3月16日的专利公告US 5,882,368(Vidrio Piaano De Mexico，S.A.DE C.V.)公开了一种使用小液滴来涂覆热玻璃基片的方法。所述公告并未提及使用冲击用于涂覆目的。
现有技术并未公开将流体分散成小液滴且使液滴冲击到待处理基片上的优点。
发明内容
本发明的目的在于提供下面的方法：涂覆是基于小液滴冲击，从而能利用小液滴的有利特征。
这通过根据权利要求1所述的特征部分的喷涂方法来实现，其中产生小液滴的流体前体材料被进给到喷雾器，喷雾器使流体雾化成小液滴。平均液滴直径的范围在0.5至5μm，且液滴速度使得液滴冲击到待涂覆表面上。对于直径通常大约0.5微米的液滴，液滴速度必须为至少100至120m/s。在正常气氛中(即并不使用在涂覆表面递送侧上的显著负压)，直径小于0.5微米的液滴冲击可实际上仅以低效率实现。当液滴大小增加时，冲击所需最小速度降低，且直径为5微米的液滴以大约20m/s的速度连续冲击。但是，就涂覆而言，优选地具有尽可能小的液滴大小，因为液滴直径对于液滴特征具有显著影响。0.5微米的液滴和100微米液滴的特征在表1中进行比较。
表1
| 特征 | 0.5μm液滴 | 100μm(雾) |
| 平均热速度(cm/s) | 5 | 0.0004 |
| 以1atm压力的重力速度(cm/s) | 0.0001 | 25 |
| 蒸发时间(s，水，100％RH) | 0.01 | ＞1000 |
| 冲击速度(m/s) | 100 | ＜1 |
| 比表面积(水，cm2/g) | 40,000 | 50 |
在根据本发明的方法中，所采用的流体前体材料包括至少一种溶剂和溶解于溶剂中的至少一种材料。溶剂可(例如)为水、乙醇或其它有机溶剂，且材料可(例如)为金属盐，诸如金属的硝酸盐、硫酸盐或氯化物或等效物。流体前体材料也可为包括至少一种单体的聚合物前体材料。
在根据本发明的方法中，液滴在喷涂腔室中喷雾，在喷涂腔室中，控制流体前体材料溶剂的蒸汽压力。在此情况下，能通过控制腔室内溶剂的蒸汽压力来操纵液滴蒸发。举例而言，以水为溶剂的原始直径5微米的液滴寿命在干燥空气(相对湿度0％)中为大约30ms，在50％相对湿度为大约50％，且在100％相对湿度超过10s。优选地，根据本发明的方法可用于控制液滴直径使得在液滴冲击到待涂覆表面上之前平均液滴直径范围为0.5至1μm。存在于液滴中的溶剂也可在冲击之前基本上完全蒸发，使得溶解于液滴中的材料(诸如金属盐)在冲击之前形成固体物品颗粒。
主要技术益处可通过将液滴冲击到待涂覆表面上而获得，因为冲击使得能使大部分液滴冲击到待涂覆表面上，导致前体材料的有效使用。液滴的斯托克数(Stokes number)必须足够高以使冲击发生，这实际上表示液滴的冲击速度取决于液滴大小。冲击机制描述于(例如)William C.Hinds，Aerosl Technology-Properties，Behavior；and Measurement of Airborne Particles，第2版，John Wiley & Sons公司，New York，1999，特别地在第121至128页。
附图说明
图1示出根据本发明的方法的实施例，同时解释了根据本发明的装置的原理。
具体实施方式
示意图1示出根据本发明的方法的实施例，即喷涂装置1，其中流体滴8喷雾到基片12面上。供气通过气体通道22经由压力调节器18引入到该装置内。所采用的气体可为惰性气体(诸如氮气N2、氩气Ar、二氧化碳CO2或氦气He)或者氧化气体(诸如氧气O2或臭氧O3)或还原气体(诸如氢气H2、一氧化碳CO或甲烷CH4)。所采用的气体也可为反应性气体，诸如氯气Cl2或者四氟化硅SiF4。气体用于使流体前体材料20的箱19加压，由此流体前体材料20流入到通道21内。流体前体材料20可为溶剂、乳剂、胶体溶液、醇盐或其它有机流体或等效物。优选地，流体前体材料20为溶解于溶剂中的金属盐，诸如溶解于甲醇中的金属的硝酸盐、硫酸盐、过氧化物或氯化物。流体前体材料20也可包括聚合物形成所需的至少一种单体或低聚物，诸如制造聚乙烯所需的乙烯，或者制造聚丙烯所需的丙烯。流体前体材料还可包括聚合引发剂和/或聚合物改性剂，诸如氯。流体前体材料从通道21进一步流动到喷雾器5的流体流动通道2。使流体20雾化所需的气体通过流动通道3和压力平衡器4流入到喷雾器5内。雾化气体可为惰性气体(诸如氮气N2、氩气Ar、二氧化碳CO2或氦气He)，氧化气体(诸如氧气O2或臭氧O3)或者还原气体(诸如氢气H2、一氧化碳CO或甲烷CH4)。雾化气体也可为反应性气体，诸如氯气Cl2或四氟化硅SiF4。由于气体流与流体流之间的速度差异，流体在雾化器端部6雾化成小液滴。平均液滴直径还在包含变径段(reducer section)7的通道中进一步减小，表示到达喷雾腔室10的流体滴8的平均直径的范围在0.5至5微米。气体流也可从通道9引入到喷雾腔室10内且(例如)用于稀释喷雾腔室10中的液滴浓度或者用于通过排放开口11使从喷雾腔室10排放的流动加速。喷雾腔室10的设计也可用于实现从排放开口11排放的流动的流率超过临界冲击速度，这在此方面指为了成功冲击到基片12上，流体滴8必须具有的最小速度。可通过将具有低浓度流体前体材料20溶剂的气体从气体通道9引入来增加流体滴8的蒸发速度。通过利用附件23加热喷雾腔室或者通过气体通道9引入热气体也实现相同效果。可通过将高浓度流体前体材料20溶剂的气体引入到喷雾腔室10内来降低流体滴8的蒸发速度。这可优选地通过从气体通道22经由流量调节器17将气体流引入到起泡器15内来达成，其中气体流穿过流体16，所述流体16优选地为流体前体材料20溶剂，由此引入到通道14内的气体流包含来自流体16的蒸汽，所述蒸汽还通过气体喷嘴13引入到喷雾腔室10内。
喷雾腔室10的形状可改变使得排放开口11可为圆形或者优选地为矩形，且流体滴、气体或蒸汽可通过连接到喷雾腔室10的若干单独喷嘴而引入到喷雾腔室10内，允许喷雾腔室10(例如)形成线状涂覆单元用于移动的幅状(web-like)基片，诸如纸、塑料、织物、金属或玻璃幅(glass web)。
对于本领域技术人员显而易见的是，本发明可具有若干实施例。因此，本发明和其实施例预期并不限于本文所述的实施例的范围而是可在由所附权利要求限定的保护范围内改变。
Claims (12)
1.一种喷涂方法，其中，产生小液滴的流体前体材料被进给到喷雾器内，所述喷雾器将流体雾化为小液滴，其特征在于，平均液滴直径的范围在0.5至5μm，且液滴的速度使得液滴被冲击到待涂覆的表面上。
2.如权利要求1所述的方法，其特征在于，液滴的速度为20至120m/s。
3.如权利要求1或2所述的方法，其特征在于，所述流体前体材料包括至少一种溶剂和溶解于溶剂中的至少一种材料。
4.如权利要求3所述的方法，其特征在于，所述溶剂是乙醇且所溶解的材料是金属盐。
5.如权利要求3所述的方法，其特征在于，所述流体前体材料包括至少一种单体。
6.如权利要求1或2所述的方法，其特征在于，所述液滴在喷雾腔室中被喷雾，在所述喷雾腔室中控制流体前体材料溶剂的蒸汽压力。
7.如前述权利要求中任一项所述的方法，其特征在于，在所述喷雾腔室中控制液滴蒸发使得在液滴冲击到待涂覆的表面上之前平均液滴直径范围在0.5至1μm。
8.如权利要求1至7中任一项所述的方法，其特征在于，在喷雾腔室中控制液滴蒸发使得存在于液滴中的溶剂在冲击之前基本上完全蒸发。
9.一种喷涂装置(1)，至少包括用于在喷雾腔室(10)中喷雾流体前体材料(20)的附件，其特征在于，所述喷雾腔室(10)至少具有用于控制喷雾腔室(10)的气氛(13)使得所述喷雾腔室(10)适应溶剂(16)的所需蒸汽压力的相关联附件，和与所述喷雾腔室(10)相关联用于喷雾所述流体前体材料使得所喷雾的流体的平均液滴大小为0.5至5微米的喷雾器(5)。
10.如权利要求9所述的装置，其特征在于，所述喷雾腔室(10)包括用于控制喷雾腔室温度在20至650℃范围的附件(23)。
11.如权利要求9或10所述的装置，其特征在于，所述喷雾腔室(10)被形成为使得在流体滴(8)冲击到基片(12)上之前流体滴(8)的速度加速。
12.如权利要求9至11中任一项所述的装置，其特征在于，所述装置包括用于将气体流引入到所述喷雾腔室(10)内的附件(9)。
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| PCT/FI2009/000045 WO2009122004A1 (en) | 2008-04-03 | 2009-04-02 | Method and apparatus for coating an article using a spray-coating method |
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| US10604302B2 (en) * | 2012-11-20 | 2020-03-31 | Altria Client Services Llc | Polymer coated paperboard container and method |
| US9530531B2 (en) | 2013-02-21 | 2016-12-27 | Nanotek Instruments, Inc. | Process for producing highly conducting and transparent films from graphene oxide-metal nanowire hybrid materials |
| US10468152B2 (en) | 2013-02-21 | 2019-11-05 | Global Graphene Group, Inc. | Highly conducting and transparent film and process for producing same |
| US20140272199A1 (en) * | 2013-03-14 | 2014-09-18 | Yi-Jun Lin | Ultrasonic spray coating of conducting and transparent films from combined graphene and conductive nano filaments |
| US8871296B2 (en) * | 2013-03-14 | 2014-10-28 | Nanotek Instruments, Inc. | Method for producing conducting and transparent films from combined graphene and conductive nano filaments |
| JP6757403B2 (ja) | 2015-08-21 | 2020-09-16 | コーニング インコーポレイテッド | ガラスを加工するための方法及び装置 |
| EP3205407B1 (de) * | 2016-02-09 | 2019-09-25 | IPR-Intelligente Peripherien für Roboter GmbH | Verfahren und anlage zur überdeckung von innenwandungen eines hohlraums mit einer schutzschicht aus korrosionsschutzwachs |
| EP3885052B1 (de) * | 2020-03-24 | 2022-11-30 | Akzenta Paneele + Profile GmbH | Randbeschichtung eines paneels mit einem beschichtungsmedium |
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| Publication number | Publication date |
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| EP2265389A1 (en) | 2010-12-29 |
| FI20080264L (fi) | 2009-10-04 |
| FI20080264A0 (fi) | 2008-04-03 |
| EP2265389A4 (en) | 2012-04-11 |
| EA201071147A1 (ru) | 2011-04-29 |
| WO2009122004A1 (en) | 2009-10-08 |
| US20110014385A1 (en) | 2011-01-20 |
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