Description:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(Section 10 and Rule 13)

1. TITLE OF THE INVENTION:
INSTRUMENT FOR APPLYING A FILM

2. APPLICANT:
Meril Corporation (I) Private Limited, an Indian company of the address Survey No. 135/139, Muktanand Marg, Bilakhia House, Pardi, Vapi, Valsad-396191 Gujarat, India.

The following specification particularly describes the invention and the manner in which it is to be performed:

FILED OF THE INVENTION
[001] The present disclosure relates to a film applicator system. More particularly, the present disclosure relates to an instrument for applying a film of varying dimensions.
BACKGROUND OF THE INVENTION
[002] A film applicator is used for applying a layer of desired material onto a substrate and have wide industrial applications. Conventionally, there are many film applicator techniques and systems known in the field. Films are applied by using various methods used by different applicators such as dip coating, spin coating, spray coating, slot die coating, rod coating, bar coating, blade coating etc.
[003] Automated film applicators incorporate complex mechatronics. The complex mechatronics requires intricate programming and expensive chipsets. Maintenance requirements for chipsets are higher and often requires specialized skills and tools for troubleshooting. Chipsets can be more susceptible to failure due to factors like voltage spikes, heat, or environmental conditions. Chipsets increase overall complexity of a film applicator leading to higher developmental cost.
[004] The chipsets and programming also increase overall complexity and cost of operation required to operate the film applicators. Conventional automated film applicators often encounter challenges related to calibration. Calibration related challenges further arises requirements of an expert with particular skillsets for fixing resulting in further increase in the cost of operations. Due to these limitations, currently available devices are difficult to use, unwieldy and costly.
[005] Hence, there arises a need of an instrument for applying a film that overcomes the problems associated with the conventional film applicator systems.
SUMMARY OF THE INVENTION
[006] Particular embodiments of the present disclosure are described herein below with reference to the accompanying drawings; however, it is to be understood that the disclosed embodiments are mere examples of the disclosure, which may be embodied in various forms. Well-known functions or constructions are not described in detail to avoid obscuring the present disclosure in unnecessary detail. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure in virtually any appropriately detailed structure.
The present disclosure relates to
[007] The present disclosure relates to an instrument for applying a film. In an embodiment, the instrument includes an upper plate, a motor, a moving element, a traverse assembly, and an adjustment assembly. The upper assembly is configured to receive a chemical solution corresponding to a film to be deposited. The moving element is coupled to the motor and is configured to move longitudinally from a first end of the upper plate towards a second end of the upper plate in response to the rotation of the motor in a pre-defined direction. The traverse assembly includes an actuator, and a swiping blade. The actuator includes a rod configured to rotate. The swiping blade is disposed over the upper plate at a distance and is coupled to the actuator. The swiping blade is configured to swipe the chemical solution over the surface of the upper plate and is configured to move vertically is response to the rotation of the rod of the actuator. The adjustment assembly includes a plate. The adjustment assembly further includes a first jaw and a second jaw coupled to the either end of the plate. At least one of the first jaw and the second jaw is moveable across at least a partial length of the plate. The traverse assembly and the adjustment assembly are operatively coupled to the moving element and are configured to move with the moving element.
[008] In an embodiment, the instrument includes a second pulley and a stroke length adjustment assembly. The second pulley includes a second drum and a second cable. The second drum has a helical channel on an outer surface of the second drum. A first end of the second cable is coupled to the second drum. A partial length of the second cable is wound over the helical channel of the second drum. The stroke length assembly is configured to adjust a length of a film to be deposited. The stroke length adjustment assembly includes a control element, a first gear, a second gear, a third gear, a vertical post and a staff. The control element is configured to toggle between a first mode and a second mode. The control element includes a first plate disposed towards a first end of the control element. The first plate is configured to be toggled between a first position and a second position, causing the control element to be in the first mode and the second mode, respectively. The first plate is rotatable. The first gear is coupled to the first plate. The first gear is configured to rotate in a first pre-defined direction in response to the rotation of the first plate in the first pre-defined direction. The second gear is coupled to the first gear. The second gear is configured to rotate in the first pre-defined direction in response to the rotation of the first gear in the first pre-defined direction. The vertical post is coupled to the third gear and is configured to rotate in response to the rotation of the third gear. The staff has a first end and a second end. The staff is coupled to the vertical post towards the first end of the staff. The staff has a notch provided at the second end of the staff. The notch is disposed within the helical channel of the second drum. The notch includes a hole configured to receive the second cable. The staff is configured to move backward in response to the rotation of the vertical post in a second pre-defined direction causing the notch to move backward within the helical channel of the second drum. In the first mode, the second gear engages with the third gear, causing the third gear to rotate in the second pre-defined direction in response to the rotation of the second gear in the first pre-defined direction. In the second mode, the second gear disengages from the third gear.
BRIEF DESCRIPTION OF DRAWINGS
[009] The summary above and the detailed description of descriptive embodiments, is better understood when read in conjunction with the apportioned drawings. For illustration of the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the disclosure is not limited to specific methods and instrumentality disclosed herein. Moreover, those in the art will understand that the drawings are not to scale.
[0010] Fig. 1a depicts an isometric view of an instrument 100, according to an embodiment of the present invention.
[0011] Fig. 1b depicts an exploded view of the instrument 100, according to an embodiment of the present invention.
[0012] Fig. 2a depicts an isometric view of a base 113, according to an embodiment of the present invention.
[0013] Fig. 2b depicts an exploded view of the base 113, according to an embodiment of the present invention.
[0014] Fig. 2c depicts a bottom perspective view of the base 113, according to an embodiment of the present invention.
[0015] Fig. 2d depicts an overflow slide 180, according to an embodiment of the present invention.
[0016] Fig. 3a depicts an isometric view of a measurement assembly 120, according to an embodiment of the present invention.
[0017] Fig. 3b depicts a traverse assembly 121, according to an embodiment of the present invention.
[0018] Fig. 3c depicts an adjustment assembly 122, according to an embodiment of the present invention.
[0019] Fig. 3d depicts an exploded view of the adjustable assembly 122, according to an embodiment of the present invention.
[0020] Fig. 4a depicts a lower housing 130, according to an embodiment of the present invention.
[0021] Fig. 4b depicts a drive assembly, according to an embodiment of the present invention.
[0022] Fig. 4c depicts a connecting shaft 160, according to an embodiment of the present invention.
[0023] Fig. 4d depicts a coupling of a moving element 111 with a first cable 201 and a second cable 211, according to an embodiment of the present invention.
[0024] Fig. 5 depicts an exploded view of an assembly a first pulley 200, a second pulley 210 and the connecting shaft 160, according to an embodiment of the present invention.
[0025] Fig. 5a depicts an assembled view of an inner assembly of the first pulley 200, according to an embodiment of the present invention.
[0026] Fig. 5b depicts an exploded view of the inner assembly of the first pulley 200, according to an embodiment of the present invention.
[0027] Fig. 5c depicts an exploded view of the inner assembly of the second pulley 210, according to an embodiment of the present invention.
[0028] Fig. 5d depicts an assembled view of the second pulley 210 with a stroke length adjustment assembly, according to an embodiment of the present invention.
[0029] Figs. 5e and 5f depict an internal view of the second pulley 210 and the stroke length adjustment assembly, according to an embodiment of the present invention.
[0030] Figs. 5g and 5h depict disengagement and engagement of a second bevel gear assembly 312, according to an embodiment of the present invention.
[0031] Fig. 6a depicts a first position of the control element 150, according to an embodiment of the present invention.
[0032] Fig. 6b depicts a second position of the control element 150, according to an embodiment of the present invention.
[0033] Fig. 6c depicts an exploded view of the control element 150, according to an embodiment of the present invention.
[0034] Fig. 7 depicts an exemplary flowchart of a method 700 for operating the instrument 100 according to an embodiment of the present invention.
[0035] Figs. 7a-7d depict various components of the instrument 100 at different stages during the operation of the instrument 100, according to an embodiment of the present invention.
DETAILED DESCRIPTION OF DRAWINGS
[0036] Prior to describing the disclosure in detail, definitions of certain words or phrases used throughout this patent document will be defined: the terms "include" and "comprise", as well as derivatives thereof, mean inclusion without limitation; the term "or" is inclusive, meaning and/or; the phrases "coupled with" and "associated therewith", as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have a property of, or the like. Definitions of certain words and phrases are provided throughout this patent document, and those of ordinary skill in the art will understand that such definitions apply in many, if not most, instances to prior as well as future uses of such defined words and phrases.
[0037] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment, but mean “one or more but not all embodiments” unless expressly specified otherwise. The terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise.
[0038] Although the operations of exemplary embodiments of the disclosed method may be described in a particular, sequential order for convenient presentation, it should be understood that the disclosed embodiments can encompass an order of operations other than the particular, sequential order disclosed. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Further, descriptions and disclosures provided in association with one particular embodiment are not limited to that embodiment, and may be applied to any embodiment disclosed herein. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed system, method, and apparatus can be used in combination with other systems, methods, and apparatuses.
[0039] Furthermore, the described features, advantages, and characteristics of the embodiments may be combined in any suitable manner. One skilled in the relevant art will recognize that the embodiments may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments. These features and advantages of the embodiments will become more fully apparent from the following description and apportioned claims, or may be learned by the practice of embodiments as set forth hereinafter.
[0040] The present disclosure relates to an instrument for applying a film. The instrument includes various components coupled with each other enabling the user to set desired dimensions (width, thickness and length) of the film to be deposited. Once the dimensions are set, the instrument can be switched on. The instrument functions automatically without any intervention by the user and applies the film of the desired dimensions. The instrument does not need any computer-based control modules and/or complex control algorithms. This makes the instrument less expensive than the conventional film applicator devices. The instrument is easy to operate. Further, the instrument enables the user to set the desired dimensions precisely using mechanical components.
[0041] Now referring to the figures, Fig. 1a illustrates an isometric view of an exemplary embodiment of an instrument 100 and Fig. 1b depicts an exploded view of the instrument 100, according to an embodiment. The instrument 100 is used to apply a film of desired dimensions. The instrument 100 is capable of applying a film of various materials such as polymer, nanomaterial, composites, biomaterial, etc. The instrument 100 includes a first end 100a and a second end 100b. The instrument 100 includes an upper housing 110, a measurement assembly 120, a lower housing 130, a motor 140, a control element 150, a connecting shaft 160, and a beam 170.
[0042] Referring now to Figs. 2a – 2c, the upper housing 110 includes a base 113, a moving element 111, and a gripper assembly 112. The upper housing 110 has a first end 110a and a second end 110b. The moving element 111 has a channel of suitable shape (e.g., U-shaped, L-shaped, V-shaped, T-shaped etc.) extending from underneath the base 113 of the upper housing 110 as depicted in Fig. 2a. A top surface of the moving element 111 is disposed below the base 113. The moving element 111 includes a threaded aperture 111b and two non-threaded apertures 111c as depicted in Fig. 2b. In an embodiment, the threaded aperture 111b is provided towards a center of the length of the moving element 111 and extends along the width of the moving element 111. The non-threaded apertures 111c are provided on either side of the threaded aperture 111b. The moving element 111 includes a post 111a provided at each end of the moving element 111 and extending vertically. The posts 111a are coupled to the measurement assembly 120 (explained later). The moving element 111 may be made of a material, such as, without limitation, stainless steel, mild steel, powder coated steel, aluminum alloy, etc. In an example implementation, the moving element 111 is made of stainless steel.
[0043] The base 113 may be made of a material, such as, without limitation, stainless steel, mild steel, powder coated steel, aluminum alloy, etc. In an example implementation, the base 113 is made of stainless steel. The base 113 is a plate of a suitable shape and size. In an embodiment, the base 113 is a plate having a generally rectangular shape and has an angular face 113b at the second end 110b and a C-section 113a at the first end 110a of the upper housing 110. The angular face 113b and the C-section 113a provides enough vertical space to the moving element 111 for linear motion. At least one plate is disposed on the base 113. In an embodiment, two plates, namely, an upper plate 114 and a lower plate 115, are stacked on the base 113.
[0044] The lower plate 115 can be fixedly or detachably coupled to the base 113 using any suitable coupling mechanism. In an embodiment, the lower plate 115 is fixedly coupled with the base 113 using riveting, fastening, welding, etc. The lower plate 115 is made of a material, such as, without limitation, metal, glass, acrylic, etc. The upper plate 114 is detachably coupled to the lower plate 115 as depicted in Fig. 2a. The upper plate 114 is configured to receive a chemical solution corresponding to the film to be deposited. In other words, the chemical solution corresponding to the film is poured on a top surface of the upper plate 114 and the film is formed on the top surface of the upper plate 114. In an embodiment, the upper plate 114 and/or the top surface of the upper plate 114 is made of a smooth material such as, but not limited to, glass, polished marble, quartzite, porcelain, acrylic, stainless steel etc. The smooth top surface of the upper plate 114 results in an even surface of the film. In an exemplary implementation, the upper plate 114 is made of glass. The upper plate 114 is grasped by the gripper assembly 112 at the second end 110b and by a stopper 116 at the first end 110a of the upper housing 110.
[0045] The moving element 111 is operatively coupled to the motor 140 and is configured to move longitudinally between the first end 110a and the second end 110b. In an embodiment, the moving element 111 is configured to move longitudinally from the first end 110a towards the second end 110b in response to the rotation of the motor 140 in a pre-defined direction. The pre-defined direction may be clockwise or anticlockwise. In an embodiment, the pre-defined direction is clockwise. The moving element 111 is coupled to a threaded shaft 117 at the bottom of the upper housing 110 via a threaded aperture 111b as depicted in Fig 2c. One end of the threaded shaft 117 passes through and couples with the threaded aperture 111b provided on the moving element 111 and the other end of the threaded shaft 117 is coupled to the angular face 113b via a rotatable bearing 113c. The threaded shaft 117 is also coupled to the motor 140 (explained later). The threaded shaft 117 is configured to translate the rotational motion of the motor 140 to a longitudinal motion of the moving element 111, thereby facilitating the linear movement of the moving element 111. This linear movement results in an even laying of the film across the top surface of the upper plate 114. The configuration of the threaded shaft 117 may be clockwise or counterclockwise depending upon the rotational direction of the motor 140. A bottom face of the C-section 113a includes a hole 113d to facilitate a rotating component (e.g., a shaft) of the motor 140 (explained later) to be coupled to the threaded shaft 117 by any suitable mechanism. Also, the C-section 113a may include dampers (not shown) or any other suitable mechanism to reduce the vibration produced by the motor 140 and its associated components during motion.
[0046] The gripper assembly 112 is coupled to the second end 110b of the upper housing 110 using a coupling mechanism such as, without limitation, pivot joint, hinge joint, condyloid joints, etc. Further, a support (not shown) of the gripper assembly 112 may be coupled (e.g., welded, screwed, riveted, hook joint, etc.) to the angular face 113b of the base 113. In an embodiment, the gripper assembly 112 is coupled to the upper housing 110 using a pivot joint. The gripper assembly 112 includes a lever 112a, a plurality of clamps, and a handle 112d. In an embodiment, the plurality of clamps includes two upper clamps 112b and two lower clamps 112c. The upper clamps 112b and the lower clamps 112c may include padded or non-padded surfaces. The upper clamps 112b and the lower clamps 112c are configured to grip the upper plate 114 of the base 113 when applying the film. The lower clamps 112c are configured to lift the upper plate 114 at a particular angle. This may be done for easily removing the upper plate 114 after completion of forming the film. One upper clamp 112b and one lower clamp 112c are coupled at each end of the lever 112a. Further, the handle 112d is coupled at either end of the lever 112a and is configured to engage or disengage the upper clamps 112b from the upper plate 114. The upper clamps 112b are configured to hold the upper plate 114 during operations to eliminate any unwanted movement due to vibrations of various mechanical components. The upper clamps 112b of the gripper assembly 112 are engaged and disengaged using a torsion spring (not shown) provided at each end of the lever 112a. The torsion spring provides a biasing force to the upper clamps 112b. The upper clamps 112b are engaged to the upper plate 114 in neutral condition, firmly gripping the upper plate 114 to its position. To disengage the upper clamps 112b from the upper plate 114 the handle 112d is pushed and rotated where the biasing nature of the torsion spring acts to disengage the upper clamps 112b from the upper plate 114.
[0047] Optionally, or in addition, the instrument 100 may include an overflow slide 180 (shown in Fig. 2d). The overflow slide 180 is coupled to the base 113 towards the second end 110b of the upper housing 110. The overflow slide 180 may be fixedly or detachably coupled to the base 113 using any suitable coupling mechanism such as snap-fit, press-fit, adhesive bonding, fastening, welding etc. In an embodiment, the overflow slide 180 is detachably coupled to the base 113 using a snap fit coupling mechanism. For example, the overflow slide 180 includes a slot 180a configured to receive a corresponding portion of the base 113. The height of the slot 180a may correspond to the height of the base 113. The overflow slide 180 includes a channel 180b extending along its length and height. The channel 180b of the overflow slide 180 is configured to provide a passage for excess chemical solution to flow out of the upper plate 114. The height of the overflow slide 180 may be designed such that the channel 180b towards a top of the overflow slide 180 aligns with the upper plate 114. The overflow slide 180 can be made from a material, such as stainless steel, mild steel, aluminum alloy, a composite of plastic and metal, etc. In an embodiment, the overflow slide 180 is made from stainless steel.
[0048] Figs. 3a-3d illustrate an exemplary measurement assembly 120 according to an embodiment. The measurement assembly 120 is coupled to the moving element 111 (explained later) such that when the moving element 111 moves, the measurement assembly 120 too moves along with it in the same direction. The measurement assembly 120 enables the user to adjust the width and the thickness of the film to be formed. The measurement assembly 120 includes a traverse assembly 121 for adjusting the thickness of the film and providing an even surface to the film. The traverse assembly 121 includes a swiping blade 121a and an actuator 121b. The swiping blade 121a and the actuator 121b are rotationally coupled (explained in details later). The swiping blade 121a is disposed over the upper plate 114 at a distance. The swiping blade 121a is configured to swipe the chemical solution from the surface of the upper plate 114 explained in details below.
[0049] The swiping blade 121a may have a shape, such as square, rectangle, rhombus, parallelogram, trapezoid, etc. In an embodiment, the swiping blade 121a has a rectangular shape. The swiping blade 121a may be made of a material such as, without limitation, metal, glass, composite material, etc. In an embodiment, the swiping blade 121a is made of stainless steel. The swiping blade 121a includes a top edge 121a1 and a lower edge 121a2. The top edge 121a1 may include a flat surface. The top edge 121a1 is configured to couple with the actuator 121b. The lower edge 121a2 may include a sharp surface. Sharp surface of the lower edge 121a2 of the swiping blade 121a is configured to provide a smooth surface to the film to be laid.
[0050] In an embodiment, the actuator 121b is a measuring instrument such as a digital micrometer. The actuator 121b and the swiping blade 121a may be detachably coupled. In an embodiment, a spindle 121c of the actuator 121b is coupled to the swiping blade 121a using any suitable coupling technique. In an example implementation, the spindle 121c includes a slot (not shown) configured to receive a portion of a top edge 121a1 of the swiping blade 121a. In an embodiment, the spindle 121c is coupled to the swiping blade 121a towards a center of the length of the top edge 121a1 of the swiping blade 121a as depicted in Fig. 3b. The traverse assembly 121 is configured to move along with the measurement assembly 120 along the length of the upper plate 114. This movement results in laying a film with an even surface due to the sharp and smooth lower edge 121a2 of the swiping blade 121a. In an embodiment, coupled the traverse assembly 121 and the moving element 111 are configured to move longitudinally in response to the longitudinal movement of the moving element 111.
[0051] The actuator 121b allows the user to measure and adjust the height of the swiping blade 121a from the upper plate 114 as desired. In an embodiment, the actuator 121b is configured to measure a distance between the lower edge 121a2 of the swiping blade 121a and the upper plate 114. The distance of the swiping blade 121a from the upper plate 114 represents the thickness of the film. The actuator 121b includes a rod 121d. The swiping blade 121a is configured to move vertically in response to the rotation of the rod 121d. To adjust the thickness of the film, the swiping blade 121a is moved in a vertical direction by rotating the rod 121d of the actuator 121b. Further, the height of the swiping blade 121a (or the thickness of the film) may be displayed on a display 121e of the actuator 121b. The user rotates the rod 121d in clockwise or anticlockwise direction as desired. The rod 121d is coupled with the spindle 121c such that in response to the rotation of the rod 121d, the spindle 121c moves vertically. Consequently, the swiping blade 121a too moves vertically. For instance, to reduce the thickness of the film the rod 121d is rotated clockwise. Clockwise rotation of the rod 121d moves the spindle 121c and the associated swiping blade 121a in a downwards direction. Similarly, to increase the thickness of the film the rod 121d is rotated in anticlockwise direction. The anticlockwise rotation of the rod 121d moves the spindle 121c and the associated swiping blade 121a in an upward direction. The display 121e depicts the adjusted height of the swiping blade 121a in real-time.
[0052] The measurement assembly 120 includes an adjustable assembly 122 coupled to the traverse assembly 121. The adjustable assembly 122 and the traverse assembly 121 are operatively coupled to the moving element 111. In an embodiment, the traverse assembly 121, the adjustable assembly 122 and the moving element 111 are configured to move together. The adjustable assembly 122 is configured to adjust the width of the film to be deposited. Figs. 3c – 3d illustrate an exemplary adjustable assembly 122. In an embodiment, the adjustable assembly 122 includes a plate 124, a scale 125, and columns 127.
[0053] The plate 124 is rectangular according to an embodiment though it can have any other suitable shape. The plate 124 may be made of a material, such as, without limitation, metal, aluminum alloy, stainless steel, composite materials, etc. In an example implementation, the plate 124 is made of stainless steel. Each end of the plate 124 is coupled to a respective column 127 of the columns 127 using a coupling mechanism, such as, without limitation, riveting, fastening, welding, etc. In an embodiment, the plate 124 is coupled to the columns 127 using a plurality of fasteners 127c. The plate 124 is coupled to the actuator 121b. For example, an opening 123 may be provided on surface of the plate 124 (shown in Fig. 3c). The spindle 121c of the actuator 121b extends through the opening 123 such that the swiping blade 121a is disposed below the plate 124. Further, a bottom face of the display 121e of the actuator 121b rests on the top surface of the plate 124.
[0054] The adjustment assembly includes a plurality of jaws. In an embodiment, the plurality of jaws includes two jaws, namely, a first jaw 126 and a second jaw 128. The first jaw 126 and the second jaw 128 are coupled at either end of the plate 124. At least one jaw of the plurality of jaws is slidably coupled to the plate 124. In an embodiment, at least one of the first jaw 126 and the second jaw 128 is slidably coupled to the plate 124 such that at least one of the first jaw 126 and the second jaw 128 are movable along at least a partial length of the plate 124. In the depicted embodiment, both the first jaw 126 and the second jaw 128 are movable along the plate 124. This allows the user to adjust the width of the film by moving at least one of the first jaw 126 and the second jaw 128 as per requirements. In an embodiment, the first jaw 126 includes a cut-out 126a. The plate 124 is inserted through the cut-out 126a of the first jaw 126. This allows transverse movement of the first jaw 126 along the plate 124. Similarly, the second jaw 128 includes a cut-out 128a. The plate 124 is inserted through the cut-out 128a of the second jaw 128, thereby allowing transversal movement of the second jaw 128 along the plate 124. The first jaw 126 and the second jaw 128 may be made of a material, such as, without limitation, metal, aluminum alloy, stainless steel, glass, composite material, etc. In an example implementation, the first jaw 126 and the second jaw 128 are made of stainless steel.
[0055] The scale 125 helps in measuring width of the film. The scale 125 includes a plurality of markings with each marking of the plurality of markings indicating a corresponding distance. The scale 125 is coupled to the plurality of jaws. For example, the scale 125 is coupled to the first jaw 126 via a slot 126b provided on the first jaw 126 using a technique such as, adhesive bonding, snap fit, press-fit, etc. In an embodiment, the scale 125 is fixedly coupled to the first jaw 126 using a snap-fit mechanism such that a marking indicating the zero distance is aligned with the slot 126b. Further, in an embodiment, the scale 125 is fixedly coupled to the first jaw 126 and slidably coupled to the second jaw 128 via a slot 128b provided on the second jaw 128 such that the scale 125 can slide horizontally through the slot 128b. This allows smooth relative movement between the second jaw 128 and the scale 125. A marking of the plurality of markings aligned with the slot 128b indicates the width of the film to be formed. Further, the second jaw 128 includes a slot 128c extending vertically and configured to receive a portion of the swiping blade 121a. Similarly, the first jaw 126 includes a slot 126c extending vertically and configured to receive a portion of the swiping blade 121a. The slot 126c can swipe over the swiping blade 121a when the first jaw 126 is moved. The slots 126c and 128c are suitably dimensioned.
[0056] In an embodiment, the measurement assembly 120 is coupled to the moving element 111 via the columns 127 using, for example, a slide-fit mechanism, though any other suitable coupling technique may be used. The columns 127 may be made of a material, such as, without limitations, metal, aluminum alloy, stainless steel, glass, composite material, etc. In an embodiment the columns 127 are made of stainless steel. Each column 127 includes a cavity 127a provided on a bottom side of the column 127. The cavity 127a is configured to receive at least a portion of the corresponding post 111a of the posts 111a. Dimensions of the cavity 127a may correspond to the dimensions of the corresponding post 111a. Consequently, when the moving element 111 moves, the swiping blade 121a, the first jaws 126 and the second jaw 128 move in the same direction. This movement helps the first jaw 126, the second jaw 128 and the swiping blade 121a to apply even thickness and width throughout the surface of the film.
[0057] Fig. 4a illustrate the lower housing 130, according to an embodiment. The lower housing 130 may have any suitable shape such as, without limitation, cuboid, rectangle, pyramid, trapezoid, rhombus, isosceles trapezoid, parallelogram, etc. In an embodiment, the lower housing 130 is cuboidal and defines an enclosing volume. The lower housing 130 encloses various components of the instrument 100 as explained below. The lower housing 130 may be made of a material such as, metal, aluminum alloy, stainless steel, composite material, etc. In an embodiment, the lower housing 130 is made of stainless steel.
[0058] The instrument 100 includes a drive assembly. The drive assembly is configured to move the moving element 111 back and forth. Fig. 4b illustrates an exemplary drive assembly. In an embodiment, the drive assembly includes the motor 140, the beam 170 and a first bevel gear assembly 190. The motor 140 is disposed within the lower housing 130. The motor 140 may be a stepper motor, a servomotor, a synchronous motor etc. running on AC power or DC power. In an embodiment, the motor 140 is a DC servomotor. The motor 140 is capable of rotating clockwise and anticlockwise. The motor 140 has suitable power rating and rotational speed. A shaft (not shown) of the motor 140 is coupled to the beam 170. The beam 170 is coupled to the threaded shaft 117 by a coupling mechanism such as bevel gear, worm gear, hypoid gears, ratchets etc. In the embodiment, the beam 170 and the threaded shaft 117 are coupled using the first bevel gear assembly 190 as depicted in Fig. 4b. As a result, when the motor 140 rotates, the threaded shaft 117 rotates. The threaded shaft 117 converts the rotational motion into a liner motion. Consequently, the moving element 111 moves linearly. Further, the motor 140 is electrically coupled to the control element 150, e.g., to a voltage regulation unit 154 provided in the control element 150 via wires 158. The wires 158 are selected of suitable ratings to meet the operational requirements. The voltage regulation unit 154 converts AC power to DC power and provides a DC voltage to the motor 140. An AC power input 157 is provided on the lower housing 130 (as shown in Fig. 1a). An AC power supply may be coupled to the AC power input 157. In an embodiment, the motor 140 may be powered by a DC power source (e.g., a DC power bank). The power transferred by the DC power source to the motor 140 may be controlled using control circuitry e.g., a battery management system (BMS) circuit in-built with the DC power bank.
[0059] Now referring to Fig. 4c, the connecting shaft 160 has a cylindrical profile extending between a first end 160a and a second end 160b. In an embodiment, the first end 160a of the connecting shaft 160 is fixedly coupled to the lower housing 130. The first end 160a of the connecting shaft 160 may be coupled to the lower housing 130 using a coupling mechanism, such as welding, riveting, clamping, etc. In an embodiment, the lower housing 130 is provided with a hole (not shown) to receive a portion of the connecting shaft 160 towards the first end 160a. Male splines (not shown) are provided on an outer surface of the said portion of the connecting shaft 160 and corresponding female splines are provided within the hole of the lower housing 130 to lock the connecting shaft 160 and the lower housing 130 with each other. This prevents rotational motion of the connecting shaft 160 and allows the second end 160b of the connecting shaft 160 to suspend. The connecting shaft 160 includes a first slot 161, a second slot 162 and a third slot 163 situated towards the first end 160a. The first slot 161 and the third slot 163 are spaced apart at a pre-defined distance. Further, the connecting shaft 160 includes a fourth slot 164 and a fifth slot 165 situated towards the second end 160b.
[0060] The instrument 100 includes a first pulley 200 and a second pulley 210 provided in the lower housing 130. In an embodiment, the first pulley 200 is coupled to the connecting shaft 160 towards the first end 160a of the connecting shaft 160 and the second pulley 210 is coupled to the connecting shaft 160 towards the second end 160b of the connecting shaft 160. Figs. 4d and 5 – 5f illustrate the first pulley 200 and the second pulley 210, according to an embodiment. The first pulley 200 includes a first cable 201 and a first drum 204. The first cable 201 may be made of a material, such as, without limitation, polyester, polypropylene, nylon, etc. In an embodiment, the first cable 201 is made of nylon. The first cable 201 has a pre-defined length and is assembled inside the first pulley 200. In an embodiment, a portion of the first cable 201 extends out of the first pulley 200. The first cable 201 includes a first end and a second end. In an embodiment, a first connector 202 is coupled to the second end of the first cable 201 that extends out of the first pulley 200 and the first end of the first cable 201 is coupled to the first drum 204 using a technique such as, without limitation, welding, brazing, riveting, screwing, knotting, clamping, bonding, adhesive, etc. In an embodiment, the first end of the first cable 201 is coupled to the first drum 204 using screwing. The first connector 202 provided at the second end of the first cable 201 is inserted into one of the non-threaded apertures 111c of the moving element 111, thereby coupling the first cable 201 and hence, the first pulley 200, with the moving element 111 (shown in Fig. 4d). Similarly, the second pulley 210 includes a second cable 211 and a second drum 214. The second cable 211 may be made of a material, such as, without limitation, polyester, polypropylene, nylon, etc. In an example implementation, the second cable 211 is made of nylon. The second cable 211 has a pre-defined length and is assembled inside the second pulley 210. In an embodiment, a portion of the second cable 211 extends out of the second pulley 210. The second cable 211 includes a first end and a second end. In an embodiment, A second connector 212 is coupled to the second end of the second cable 211 that extends out of the second pulley 210 and the first end of the second cable 211 is coupled to the second drum 214 using a technique such as, without limitation, welding, brazing, riveting, screwing, knotting, clamping, bonding, adhesive, etc. In an embodiment, the other end of the second cable 211 is coupled to the second drum 214 using screwing. The second connector 212 is inserted into one of the non-threaded apertures 111c of the moving element 111, thereby coupling the second cable 211 and hence, the second pulley 210, to the moving element 111 (shown in Fig. 4d). In an embodiment, the second pulley 210 has a larger width than the first pulley 200. The connecting shaft 160 provides support to the first pulley 200 and the second pulley 210.
[0061] Referring now to Figs. 5 - 5b, the first pulley 200 includes a first torsion spring 203 and a first casing 205. A partial length of the first cable 201 is wound on the first drum 204. The first drum 204 is coupled to the connecting shaft 160. The first drum 204 is operatively coupled to the connecting shaft 160 such that the first drum 204 is able to freely rotate during the operation of the instrument 100. In an embodiment, a bearing (not shown) is provided on the portion of the connecting shaft 160 disposed inside the first drum 204. The first drum 204 rests on the bearing. The bearing allows the first drum 204 to rotate freely. In an embodiment, the first drum 204 is cylindrical, though it may have any other suitable shape. In an embodiment, the first drum 204 has a smooth outer surface. The first torsion spring 203 is disposed over a section of the connecting shaft 160 having the second slot 162. The first torsion spring 203 may be made of a material, such as, without limitation, carbon steel, stainless steel, specialty alloy, titanium, chromium vanadium steel, chromium silicone steel, copper alloy, nickel, etc. In an example implementation, the first torsion spring 203 is made of stainless steel. One end of the first torsion spring 203 is coupled to the connecting shaft 160 using a technique, such as, crimping, screwing, welding, riveting, etc. In an example implementation, one end of the first torsion spring 203 is coupled to the second slot 162 the connecting shaft 160 using crimping. The other end of the first torsion spring 203 is coupled to a first peg 206 provided on the first drum 204. In an embodiment, the other end of the first torsion spring 203 is crimped on the first peg 206. The first torsion spring 203 is configured to rewind the first drum 204, thereby facilitating to rewind the first cable 201 on the first drum 204 and retract the first cable 201 within the first pulley 200 (explained later). In an embodiment, the first drum 204, and the first torsion spring 203 are disposed within the first casing 205. The first casing 205 is shaped and dimensioned accordingly. In an embodiment, the first casing 205 is generally cylindrical having circular discs at either end. The first casing 205 may be made of a material, such as, without limitation, metal, aluminum alloy, stainless steel, composite materials, etc. In an example implementation, the first casing 205 is made of stainless steel. The first casing 205 is coupled to the connecting shaft 160 via a slot-fit mechanism although other coupling mechanism can be used. In an embodiment, the first casing 205 is coupled to the first slot 161 and the third slot 163 of the connecting shaft 160 facilitated by a male and a female locking mechanism (not shown).
[0062] Now referring to Figs. 5, 5c - 5f, the second pulley 210 includes a second torsion spring 213, and a second casing 215. The second drum 214 is coupled to the connecting shaft 160). The second drum 214 is operatively coupled to the connecting shaft 160 via the fourth slot 164 such that the second drum 214 is able to freely rotate during the operation of the instrument 100. In an embodiment, a bearing (not shown) is provided on a portion of the connecting shaft 160 disposed inside the second drum 214. The second drum 214 rests on the bearing. The bearing allows the second drum 214 to rotate freely. The second drum 214 is cylindrical, though it may have any other suitable shape. In an embodiment, the second drum 214 has a helical channeled outer surface. A partial length of the second cable 211 is wound on the helical channel of the second drum 214. The second torsion spring 213 is disposed over a section of the connecting shaft 160 having the fifth slot 165. The second torsion spring 213 may be made of a material, such as, without limitation, carbon steel, stainless steel, specialty alloy, titanium, chromium vanadium steel, chromium silicone steel, copper alloy, nickel, etc. In an example implementation, the second torsion spring 213 is made of stainless steel. One end of the second torsion spring 213 is coupled to the connecting shaft 160 using a technique, such as crimping, screwing, welding, riveting, etc. In an example implementation, one end of the second torsion spring 213 is coupled to the fifth slot 165 of the connecting shaft 160 using crimping. The other end of the second torsion spring 213 is coupled to a second peg 216 provided on the second drum 214. In an embodiment, the other end of the second torsion spring 213 is crimped on the second peg 216. The second torsion spring 213 is configured to rewind the second drum 214, thereby facilitating to rewind the second cable 211 on the second drum 214 and retract the second cable 211 within the second pulley 210 (explained later). In an embodiment, the second drum 214, and the second torsion spring 213 are disposed within the second casing 215. The second casing 215 is shaped and dimensioned accordingly. In an embodiment, the second casing 215 is generally cylindrical having circular discs at either end. The second casing 215 may be made of a material, such as, without limitation, metal, aluminum alloy, stainless steel, composite materials, etc. In an example implementation, the second casing 215 is made of stainless steel. At least a portion of the second casing 215 is coupled to the connecting shaft 160. In an embodiment, one end of the second casing 215 is coupled to the fourth slot 164.
[0063] Further, according to an embodiment, the second pulley 210 is coupled to a stroke length adjustment assembly configured to set or adjust the length of the film to be deposited. An exemplary embodiment of the stroke adjustment mechanism is depicted in Figs. 5d – 5f. The stroke length adjustment mechanism includes a central shaft 300. In an embodiment, the central shaft 300 is cylindrical, though it may have any other shape. A first end of the central shaft 300 is coupled to the control element 150 using a technique such as, riveting, bonding, screwing, welding, etc. A second end of the central shaft 300 is coupled to a first gear 303. The first gear 303 is coupled to a second gear 304 via respective teeth. The second gear 304 is mounted over a platform 302. One end of the platform 302 is coupled to the lower housing 130 using a coupling technique such as, without limitation, riveting, bonding, etc. In an embodiment, the platform 302 has two or more rods (not shown) disposed inside corresponding rods (not shown) provided in the lower housing 130. The platform 302 and the central shaft 300 are coupled using a channel 310. In an embodiment, the channel 310 has a L shape, though it may have any other suitable shape. The channel 310 is fixedly coupled at a first end to the platform 302. A second end of the channel 310 includes a slot configured to receive the central shaft 300. Dimensions of the slot of the channel 310 are such that the central shaft 300 can rotate freely. The second gear 304 is operatively coupled to a third gear 305 via respective teeth. The first gear 303, the second gear 304 and the third gear 305 form a second bevel gear assembly 312 as depicted in Fig. 5d. It should be noted that the third gear 305 is not shown in Fig. 5e for reasons of clarity.
[0064] Now referring to Figs. 5g – 5h, the central shaft 300 is configured to move forward and backward in response to a motion of the control element 150 (explained later). In response to the movement of the central shaft 300, the platform 302 is configured to move forward and backwards in the same direction as that of the central shaft 300. In an embodiment, the platform 302 includes a sliding mechanism (not shown) to facilitate the movement of the platform 302.
[0065] A rod 301 extends from the first gear 303. A first end of the rod 301 is coupled to the first gear 303 such that when the first gear 303 rotates, the rod 301 remains stationary. The third gear 305 is disposed over the rod 301 towards a second end of the rod 301. The third gear 305 is coupled to a vertical post 306 via a shaft 311. A first end of the shaft 311 is coupled to the rotating portion of the third gear 305 such that the vertical post 306 is configured to rotate in response to the rotation of the third gear 305. The shaft 311 includes a hollow cavity. The dimensions of the hollow cavity of the shaft 311 are such that the rod 301 can move inside freely. A second end of the shaft 311 is coupled to a vertical post 306. The vertical post 306 is configured to rotate with the shaft 311 and the third gear 305. The vertical post 306 may have a shape, such as rectangular, cuboid, square, etc. In an embodiment, the vertical post 306 has a generally rectangular shape. A claw 309 is fixedly coupled to the rod 301 at a second end of the rod 301 (shown in Fig. 5e). The length of the rod 301 is designed such that the claw 309 is disposed within a cavity provided in the second drum 214. The claw 309 includes two or more jaws configured to removably grip an internal shaft (not shown) disposed within the cavity of the second drum 214. In an embodiment, the two or more jaws are configured to move radially outward in response to the forward motion of the rod 301, thereby releasing the internal shaft and disengaging the second drum 214 from the vertical post 306. The two or more jaws are configured to move radially inward in response to the backward motion of the rod 301, thereby gripping the internal shaft and operatively coupling the second drum 214 with the vertical post 306.
[0066] The stroke length adjustment assembly includes a staff 307 having a first end and a second end. The staff 307 is coupled to a top end of the vertical post 306. For example, the vertical post 306 is coupled to the staff 307 towards the first end of the staff 307. In an embodiment, the staff 307 is cylindrical, though it may have any other suitable shape. A hole (not shown) may be provided on the vertical post 306 towards the top end of the vertical post 306 to receive a portion of the staff 307. The staff 307 is configured to move linearly in response to the rotation of the vertical post 306. For example, the staff 307 moves forward when the vertical post 306 rotates in a first pre-defined direction (e.g., clockwise) and moves backward when the vertical post 306 rotates in a second pre-defined direction (e.g., anticlockwise) causing the notch 308 to move backward within the helical channel of the second drum 214. The vertical post 306 may include a friction based sliding mechanism such as a sleeve bearing, to convert the rotational motion of the vertical post 306 to the linear motion of the staff 307. A notch 308 is provided towards the second end of the staff 307. The notch 308 is disposed within and engages the helical channel of the second drum 214. The notch 308 is configured to move within the helical channel of the second drum 214 in response to the linear movement of the staff 307 (when the third gear 305 rotates, e.g., in anticlockwise direction, while setting the stroke length). The user may rotate the third gear 305 in an opposite direction, e.g., in clockwise direction, once the film is formed to return the notch 308 to original position. The notch 308 may have a pre-defined shape, such as, without limitation, V-shaped, U-shaped, C-shaped, etc. In an example implementation, the notch 308 is V-shaped. The shape of the notch 308 may correspond to the shape of the helical channel of the second drum 214. The notch 308 includes a hole (not shown) configured to receive the second cable 211. The second cable 211 is inserted through the hole. The hole is dimensioned such that the second cable 211 can easily pass through the hole during the operation of the instrument 100. The notch 308 ensures the alignment and creates tension in the second cable 211 once the decided length is covered. The operation of the stroke length adjustment assembly can be controlled using the control element 150 as explained later.
[0067] The control element 150 enables the user to set the stroke length (i.e., the length of the film to be deposited) and control the speed of the motor 140. In an embodiment, the control element 150 is configured to be toggled between a first mode and a second mode. In the first mode, the control element 150 is configured to control the stroke length adjustment assembly to set the length of the film to be deposited. In the second mode, the control element 150 is configured to control voltage provided to the motor 140, thereby adjusting the speed of the motor 140. The motor 140 is configured to rotate in the second mode at a pre-defined speed adjusted by the control element 150. The control element 150 is coupled to the lower housing 130. Figs. 6a – 6c illustrates the control element 150 according to an embodiment. The control element 150 has a first end 150a and a second end 150b. The control element 150 includes a first plate 151 disposed towards the first end 150a, a second plate 152 disposed towards the second end 150b, a spring 153 (shown in Fig. 6c) and a voltage regulation unit 154. In an embodiment, the voltage regulation unit 154 includes a rectifier circuit configured to convert the AC power supply to a DC power supply for the motor 140. The voltage output by the voltage regulation unit 154 is controlled by the control element 150 as explained later. The voltage regulation unit 154 is disposed in a corresponding slot provided in the lower housing 130.
[0068] The first plate 151 is configured to be toggled between a first position and a second position. The first position of the first plate 151 causes the control element 150 to be in the first mode and the second position of the first plate 151 causes the control element 150 to be in the second mode. Further, the first plate 151 is rotatable. The first plate 151 includes a notch 155 configured to couple with a slot 156 provided in the second plate 152. In an embodiment, the first plate 151 has a circular shape, though it may have any other suitable shape. The first plate 151 may be made of a material, such as, without limitation, nylon, polyether, polyurethane, polypropylene, Acrylonitrile Butadiene Styrene (ABS), steel covered by a protective insulating material, etc. In an example implementation, the first plate 151 is made of polypropylene. In an embodiment, the second plate 152 has a circular shape, though it may have any other suitable shape. The second plate 152 may be made of a material, such as, without limitation, nylon, polyether, polyurethane, polypropylene, Acrylonitrile Butadiene Styrene (ABS), steel covered by a protective insulating material, etc. In an example implementation, the second plate 152 is made of polypropylene. The second plate 152 includes an aperture 152a. The aperture 152a is configured to receive the central shaft 300 and the spring 153. The spring 153 is disposed over the central shaft 300 between the first plate 151 and the second plate 152. The spring 153 enables the first plate 151 to switch between a first position and a second position as depicted in Figs. 6a-6b respectively. To set the length of the film, the first plate 151 is set to the first position, for example, by pressing the control element 150. When the control element 150 is pressed, the notch 155 of the first plate 151 engages with the slot 156 of the second plate 152, thereby setting the first plate 151 to the first position. The spring 153 disposed between the first plate 151 and the second plate 152 is compressed when the control element 150 is set in the first position. Compression of the spring 153 provides retractability to the first plate 151 when in the first position.
[0069] The first plate 151 is coupled to the first end of the central shaft 300 and is operatively coupled to the first gear 303 via the central shaft 300. The central shaft 300 and the first gear 303 are configured to rotate in response to the rotation of the first plate 151. The central shaft 300, the first gear 303 and the second gear 304 are configured to move forward and backward) in response to the first plate 151 being set in the first position and the second position, respectively.
[0070] In response to the first plate 151 set in the first position, the central shaft 300, and the first gear 303 moves forward. Consequently, the platform 302 also moves forward. This couples the second gear 304 with the third gear 305 (as depicted in Fig. 5h). When the first gear 303 moves in the forward direction, the rod 301 also moves in forward direction. The first position of the first plate 151 causes the control element 150 to be in the first mode. In response to the first plate 151 being in the first position, the central shaft 300 is configured to move forward. As the platform 302 is configured to move with the central shaft 300, when the first plate is in the first position, the forward movement of the platform 302 causes the second gear 304 to engage with the third gear 305 and causing the third gear 305 to rotate in the second pre-defined direction in response to the rotation of the second gear 304 in the first pre-defined direction. The forward motion of the rod 301 disengages the claw 309 from the internal shaft of the second drum 214 resting on the connecting shaft 160. Thus, the second drum 214 remains stationary while setting the stroke length. Further, when the first plate 151 is pressed, an activator (not shown) provided in the control element 150 is deactivated. The activator is electrically coupled to the voltage regulation unit 154 and the motor 140. When the activator is deactivated, the activator disconnects the voltage regulation unit 154 from the motor 140. For example, in the first mode the activator is configured to disconnect the voltage regulation unit 154 from the motor 140 and in the second mode, the actuator is configured to connect the voltage regulation unit 154 with the motor 140. The activator may be a toggle switch, a rocker switch, a push button switch, a rotatory switch, a slide switch, dip switch, etc. In an example implementation, the activator is an internal toggle switch. The user may need to keep the first plate 151 pressed while setting the stroke length.
[0071] Further, the user rotates the first plate 151 in a pre-defined direction (e.g., in the clockwise direction) to define the length of the film. The first plate 151 may have a plurality of first indicators with each first indicator of the plurality of first indicators indicating a corresponding length of the film in desired units (e.g., in millimetres, centimetres, inches, etc.). In an embodiment, each rotation of the first plate 151 may set a pre-defined length of the film. For example, one rotation of the first plate 151 sets the length of the film to 10 inches. The pre-defined length depends upon the diameter of the helical channel, number of turns of the helix channel, the pitch of the helix channel and the like. In an example implementation, the instrument 100 may be used to set the length of the film up to 80 inches.
[0072] In response to the rotation of the first plate 151 in the pre-defined direction, the central shaft 300 and the first gear 303 rotate in the pre-defined direction. Due to the coupling of the first gear 303, the second gear 304 and the third gear 305 (as shown in Fig. 5d), the third gear 305 rotates in a direction opposite to the pre-defined direction (e.g., in the anticlockwise direction). Consequently, the vertical post 306 also moves in the same direction of the third gear 305, which causes the staff 307 to move longitudinally. For example, when the vertical post 306 rotates in the anticlockwise direction, the staff 307 moves backward. Further, the notch 308 traces the helical channel of the second drum 214 in a backward direction. Various components are designed such that one rotation of the first plate 151 causes the vertical post 306 to complete one rotation and the notch 308 to trace one coil of the helical channel of the second drum 214. The notch 308 is disposed on the helical channels of the second drum 214 such that when the second cable 211 is unwrapped a tension is created opposing further release of the second cable 211. Backward rotation of the notch 308 allows an increased length of the second cable 211 to be unwrapped without the tension created by the notch 308. This tension free unwrapping of the length of the second cable 211 defines the length of the film to be laid by providing a distance to the moving element 111 to travel towards the second end 100b of the instrument 100. In an embodiment, the tension generated by the notch 308 upon reaching an initial position can suspend further rotation of the motor 140.
[0073] In the second mode, the control element 150 is configured to set the voltage provided to the motor 140, thereby adjusting the speed of the motor 140. To set the voltage provided to the motor 140, the first plate 151 is set to the second position, for example, by releasing the first plate 151. When the first plate 151 is released, the spring 153 exerts an expansion force and as a result, the notch 155 of the first plate 151 disengages from the slot 156 of the second plate 152, and the first plate 151 moves slightly backwards, thereby setting the first plate 151 in the second position (as shown in Fig. 6b). In response to the first plate 151 being in the second position, the central shaft 300 is configured to move backwards. As the platform 302 is configured to move with the central shaft 300, when the first plate 151 is in the second position (i.e., when the control element 150 is in the second mode), the backward movement of the platform 302 causes the second gear 304 to disengage from the third gear 305. As a result, the activator is activated, which connects the voltage regulation unit 154 with the motor 140. The control element 150 may have a plurality of second indicators with each second indicator of the plurality of second indicators indicating a rotational speed of the motor 140, for example, in rpm.
[0074] Further, in the second mode of operations, the rotation of the first plate 151 causes a voltage provided to the motor 140 to increase or decrease depending upon the rotational direction of the first plate 151. In an embodiment, the user may rotate the first plate 151 in a clockwise direction to increase the voltage and in anticlockwise to decrease the voltage supplied to the motor 140, thereby increase or decreasing the rotational speed of the motor 140, respectively. In another embodiment, the user may rotate the first plate 151 in the anticlockwise direction to increase the voltage and in the clockwise direction to decrease the voltage.
[0075] Fig. 7 illustrates a flowchart of a method 700 of operating the instrument 100 according to an embodiment. The instrument 100 is used to lay films, for example, polymeric films for medical as well as non-medical applications.
[0076] At step 701, the width of the film to be deposited is set. The first jaw 126 or the second jaw 128 or both are moved laterally along the length of the plate 124 and set to a desired width. The scale 125 provides accurate measuring units for the width of the film. Fig. 7a and Fig. 7b illustrate two exemplary positions of the first jaw 126 and the second jaw 128.
[0077] At step 702, the thickness of the film to be deposited is set. To set the thickness of the film, the rod 121d of the actuator 121b is rotated. In an embodiment, to increase the thickness of the film, the rod 121d is rotated in the anticlockwise direction or to reduce the thickness, the rod 121d is rotated in the clockwise direction. When the user rotates the rod 121d in the anticlockwise direction, the spindle 121c and the swiping blade 121a move upwards, thereby increasing the thickness of the film to be deposited. Similarly, when the user rotates the rod 121d in the clockwise direction, the spindle 121c and the swiping blade 121a move downwards, thereby decreasing the thickness of the film.
[0078] At step 703, the length of the film to be deposited is set with the help of the stroke length adjustment mechanism. For example, to set the length of the film, the user pushes and rotates the first plate 151 in a pre-defined (e.g., anticlockwise) direction. The stroke adjustment assembly is activated and the length of the film is set as described in details earlier.
[0079] At step 704, a chemical solution 410 corresponding to the film to be deposited is poured on the upper plate 114 of the base 113 from a container 400 having the chemical solution 410 as depicted in Fig. 7c.
[0080] At step 705, the instrument 100 is powered on, for example, by pushing the control element 150. Further, the rotational speed of the motor 140 is set as explained earlier. When the instrument is switched on, the motor 140 starts rotating, which causes the beam 170 to rotate. Consequently, the first bevel gear assembly 190 is activated and the threaded shaft 117 rotates. The threaded shaft 117 translates the rotational motion into a linear motion. As a result, the moving element 111 moves from the first end 100a of the instrument 100 towards the second end 100b of the instrument 100. The measurement assembly 120 including the swiping blade 121a moves along with the moving element 111. The movement of the swiping blade 121a swipes the chemical solution 410 to form an exemplary film 500. The horizontal movement of the moving element 111 is controlled by adjusting the voltage provided to the motor 140. The exemplary film 500 deposited on the upper plate 114 is depicted in Fig. 7d.
[0081] As the moving element 111 moves forward longitudinally, the first drum 204 and the second drum 214 rotates alongside and hence the first cable 201 and the second cable 211 start unwinding from the first drum 204 and the second drum 214, respectively. The unwinding of the first cable 201 and the second cable 211 cause the first drum 204 and the second drum 214, respectively, to rotate. Consequently, the first torsion spring 203 and the second torsion spring 213 move to a compressed state causing the compressional force to build. The rotation of the second drum 214 causes the staff 307 to move forward and the notch 308 traces the helical channel on the second drum 214 in the forward direction. Upon reaching the set length, the notch 308 provided on the staff 307 reaches an initial position (e.g., reaches the first loop of the helical channel of the second drum 214) and causes tension in the second cable 211. The notch 308 resists further release of the second cable 211 from the helical channel of the second drum 214. As a result, the motor 140 stops rotating after experiencing opposing force due to the tension.
[0082] At step 706, the operation of the instrument 100 is terminated. For example, when the motor 140 stops rotating, the user rotates the first plate 151 to its initial position. This causes the motor 140 to rotate in the opposite direction. Further, the first torsion spring 203 and the second torsion spring 213 exert the compression force, which causes the first drum 204 and the second drum 214 to rotate in the opposite direction and retract the first drum 204 and the second drum to respective initial positions. This causes to the retraction of the first cable 201 and the second cable 211 back inside the first pulley 200 and the second pulley 210 respectively and rewind on the first drum 204 and the second drum 214, respectively. The retraction of the first cable 201 and the second cable 211 also moves the moving element 111 and the traverse assembly 121 towards respective initial positions. The user switches off the motor 140 and thereby, the instrument 100, by pressing the control element 150 again.
[0083] Once the process is complete, i.e., the film 500 is deposited on the upper plate 114, the upper clamps 112b are disengaged from the upper plate 114. Any extra amount of the chemical solution 410 remaining on the upper plate 114, flows out from the overflow slide 180 provided towards the second end 110b of the upper housing 110. The adjustment assembly may be decoupled from the base 113 by lifting off the adjustment assembly from the posts 111a. The upper plate 114 may be lifted from the base 113 by operating the gripper assembly 112. The film 500 thus deposited is uniform and has precise dimensions (length, width and height) set by the user with the help of various components of the instrument 100.
[0084] The present disclosure presents several advantages over conventional film applicator devices. The proposed instrument enables the user to set the height, width and the length of the film easily and precisely. With the help of mechanical adjustment assemblies to set the dimensions of the film, computerized control assembly is avoided, which reduces the complexity and cost of the proposed instrument.
[0085] The scope of the invention is only limited by the appended patent claims. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present invention is/are used. , Claims:WE CLAIM:
1. An instrument (100) for applying a film, the instrument (100) comprising:
a. an upper plate (114) configured to receive a chemical solution corresponding to a film to be deposited;
b. a motor (140);
c. a moving element (111) coupled to the motor (140) and configured to move longitudinally from a first end of the upper plate (114) towards a second end of the upper plate (114) in response to the rotation of the motor (140) in a pre-defined direction;
d. a traverse assembly (121) comprising:
i. an actuator (121b) comprising a rod (121d);
ii. a swiping blade (121a) disposed over the upper plate (114) at a distance and coupled to the actuator (121b), the swiping blade (121a) is configured to swipe the chemical solution and is configured to move vertically in response to the rotation of the rod (121d);
e. an adjustment assembly (122) comprising:
i. a plate (124); and
ii. a first jaw (126) and a second jaw (128) coupled to the plate (124) at either end of the plate (124), at least one of the first jaw (126) and the second jaw (128) being movable across at least a partial length of the plate (124);
f. wherein the traverse assembly (121) and the adjustment assembly (122) are operatively coupled to the moving element (111) and are configured to move with the moving element (111).
2. The instrument (100) as claimed in claim 1, wherein the actuator (121b) is configured to measure a distance between a lower edge (121a2) of the swiping blade (121a) and the upper plate (114).
3. The instrument (100) as claimed in claim 1, wherein the actuator (121b) comprises a spindle (121c) coupled to the rod (121d) and the swiping blade (121a), the spindle (121c) is configured to move vertically in response to the rotation of the rod (121d), causing the swiping blade (121a) to move vertically.
4. The instrument (100) as claimed in claim 3, wherein the spindle (121c) extends through an opening (123) provided on the plate (124).
5. The instrument (100) as claimed in claim 1, wherein the actuator (121b) is a measuring instrument.
6. The instrument (100) as claimed in claim 1, wherein the adjustment assembly (122) comprises columns (127), each column (127) of the columns (127) is coupled to an end of the plate (124) and has a cavity (127a) provided on a bottom side of the column (127), the cavity (127a) is configured to receive at least a portion of a corresponding post (111a) provided on the moving element (111).
7. The instrument (100) as claimed in claim 1, wherein the adjustment assembly (122) comprises a scale (125) fixedly coupled to the first jaw (126) and slidably coupled to the second jaw (128), the scale (125) comprising a plurality of markings, each marking of the plurality of markings indicating a corresponding distance.
8. The instrument (100) as claimed in claim 1, wherein the instrument (100) comprises a threaded shaft (117) coupled to the motor (140) and the moving element (111), the threaded shaft (117) configured to translate the rotational motion of the motor (140) to the longitudinal motion of the moving element (111).
9. The instrument (100) as claimed in claim 8, wherein the instrument (100) comprises a beam (170) coupled to the motor (140) and coupled to the threaded shaft (117) via a first bevel gear assembly (190).
10. The instrument (100) as claimed in claim 8, wherein the threaded shaft (117) passes through and couples with a threaded aperture (111b) provided on the moving element (111).
11. The instrument (100) as claimed in claim 1, wherein the instrument (100) includes a gripper assembly (112) comprising:
a. a lever (112a);
b. upper clamps (112b) and lower clamps (112c) configured to grip the upper plate (114), one of the upper clamps (112b) and one of the lower clamps (112c) are coupled to each end of the lever (112a); and
c. a handle (112d) coupled to the lever (112a) and configured to engage or disengage the upper clamps (112b) from the upper plate (114) using a torsion spring provided at each end of the lever (112a).
12. The instrument (100) as claimed in claim 1, wherein the instrument (100) includes an overflow slide (180) comprising a channel (180b) configured to to provide a passage for excess chemical solution to flow out of the upper plate (114).
13. The instrument (100) as claimed in claim 1, wherein the instrument (100) includes:
a. a first pulley (200) comprising:
i. a first drum (204); and
ii. a first cable (201) having a first end coupled to the first drum (204) and a second end coupled to the moving element (111), a partial length of the first cable (201) being wound on the first drum (204);
b. a second pulley (210) comprising:
i. a second drum (214); and
ii. a second cable (211) having a first end coupled to the second drum (214) and a second end coupled to the moving element (111), a partial length of the second cable (211) being wound on the second drum (214);
c. wherein the first drum (204) and the second drum (214) are configured to rotate in response to longitudinal movement of the moving element (111), causing the first cable (201) and the second cable (211) to unwind from the first drum (204) and the second drum (214), respectively.
14. The instrument (100) as claimed in claim 13, wherein the second pulley (210) comprises a second torsion spring (213) coupled to the second drum (214) and wherein the first pulley (200) comprises a first torsion spring (203) coupled to the first drum (204), wherein the second torsion spring (213) and the first torsion spring (203) are configured to retract the second drum (214) and the first drum (204) to respective initial positions, causing the second cable (211) and the first cable (201) to rewind on the second drum (214) and the first drum (204), respectively.
15. An instrument (100) for applying a film, the instrument (100) comprising:
a. a second pulley (210) comprising:
i. a second drum (214) having a helical channel on an outer surface of the second drum (214); and
ii. a second cable (211) having a first end coupled to the second drum (214), a partial length of the second cable (211) being wound on the helical channel of the second drum (214);
b. a stroke length adjustment assembly configured to adjust a length of a film to be deposited, the stroke length adjustment assembly comprising:
i. a control element (150) configured to be toggled between a first mode and a second mode, the control element (150) comprising a first plate (151) disposed towards a first end (150a) of the control element (150) and configured to be toggled between a first position and a second position, causing the control element (150) to be in the first mode and the second mode, respectively, the first plate (151) being rotatable;
ii. a first gear (303) coupled to the first plate (151) and configured to rotate in a first pre-defined direction in response to the rotation of the first plate (151) in a first pre-defined direction;
iii. a second gear (304) coupled to the first gear (303) and configured to rotate in the first pre-defined direction in response to the rotation of the first gear (303) in the first pre-defined direction;
iv. a third gear (305);
v. a vertical post (306) coupled to the third gear (305) and configured to rotate in response to the rotation of the third gear (305);
vi. a staff (307) having a first end and a second end; the staff (307) having a notch (308) provided at the second end of the staff and disposed within a helical channel of the second drum (214), the notch (308) having a hole configured to receive the second cable (211), the staff (307) is coupled to the vertical post (306) towards the first end of the staff (307) and the staff (307) is configured to move backward in response to the rotation of the vertical post (306) in a second pre-defined direction, causing the notch (308) to move backward within the helical channel of the second drum (214);
vii. wherein, in the first mode, the second gear (304) engages with the third gear (305), causing the third gear (305) to rotate in the second pre-defined direction in response to the rotation of the second gear (304) in the first pre-defined direction;
viii. wherein, in the second mode, the second gear (304) disengages from the third gear (305).
16. The instrument (100) as claimed in claim 15, wherein when the vertical post (306) completes one rotation, the notch (308) traces one loop of the helical channel of the second drum (214).
17. The instrument (100) as claimed in claim 15, wherein the stroke length adjustment assembly comprises a central shaft (300) having a first end coupled to the first plate (151) and a second end coupled to the first gear (303), the central shaft (300) configured to rotate in response to the rotation of the first plate (151) and configured to move forward and backward in response to the first plate (151) being set to the first position and the second position, respectively.
18. The instrument (100) as claimed in claim 17, wherein the second gear (304) is mounted on a platform (302) coupled to the central shaft (300), the platform (302) configured to move with the central shaft (300), thereby causing the second gear (304) to engage or disengage with the third gear (305) when the first plate (151) is in the first position or the second position, respectively.
19. The instrument (100) as claimed in claim 15, wherein the stroke length adjustment assembly comprises:
a. a rod (301) having a first end coupled to the first gear (303); and
b. a claw (309) coupled to a second end of the rod (301), the claw (309) comprising two or more jaws configured to removably grip an internal shaft of the second drum (214), wherein in the first position, the rod (301) moves forward, causing the two or more jaws to release the internal shaft of the second drum (214) and wherein in the second position, the rod (301) moves backward, causing the two or more jaws to grip the internal shaft of the second drum (214).
20. The instrument (100) as claimed in claim 15, wherein the first plate (151) comprises a notch (155), wherein the control element (150) comprises a second plate (152) disposed towards a second end (150b) of the control element (150) and comprising a slot (156), wherein in the first position, the notch (155) engages with the slot (156) and in the second position, the notch (155) disengages from the slot (156).
21. The instrument (100) as claimed in claim 15, wherein the control element (150) comprises a spring (153) disposed between the first plate (151) and the second plate (152).
22. The instrument (100) as claimed in claim 15, wherein the control element (150) comprises an activator electrically coupled to a motor (140) and a voltage regulation unit (154), wherein in the first mode, the activator is configured to disconnect the voltage regulation unit (154) from the motor (140) and in the second mode, the actuator is configured to connect the voltage regulation unit (154) with the motor (140).
23. The instrument (100) as claimed in claim 15, wherein the first plate (151) comprises a plurality of first indicators, each of the plurality of first indicators indicating a corresponding length of the film to be set.
24. The instrument (100) as claimed in claim 15, the instrument (100) comprising:
a. an upper plate (114) configured to receive a chemical solution corresponding to a film to be deposited;
b. a motor (140) electrically coupled to the control element (150) and configured to rotate in the second mode;
c. a moving element (111) coupled to the motor (140) and configured to move longitudinally from a first end of the upper plate (114) towards a second end of the upper plate (114) in response to the rotation of the motor (140) in a pre-defined direction;
d. a traverse assembly (121) coupled to the moving element (111) and configured to move longitudinally in response to the longitudinal movement of the moving element (111), the traverse assembly (121) comprising a swiping blade (121a) disposed over the upper plate (114) at a distance and configured to swipe the chemical solution;
25. The instrument (100) as claimed in claim 24, wherein in the second mode, the rotation of the first plate (151) causes a voltage provided to the motor (140) to increase or decrease depending upon the rotational direction of the first plate (151).
26. The instrument (100) as claimed in claim 24, wherein in the second mode, the notch (308), upon reaching an initial position, is configured to generate tension in the second cable (211) causing the motor (140) to stop rotating.
27. The instrument (100) as claimed in claim 15, wherein the instrument (100) comprises a connecting shaft (160) having a first end (160a) fixedly coupled to a lower housing (130), wherein the second pulley (210) is coupled to the connecting shaft (160) towards a second end (160b) of the connecting shaft (160).
28. The instrument (100) as claimed in claim 15, wherein the instrument (100) comprises:
a. a first pulley (200) coupled to the connecting shaft (160) towards the first end (160a) of the connecting shaft (160), the first pulley (200) comprising:
i. a first drum (204); and
ii. a first cable (201) having a first end coupled to the first drum (204), a partial length of the first cable (201) being wound on the first drum (204);
b. wherein a second end of the first cable (201) and a second end of the second cable (211) are coupled to a moving element (111);
c. wherein in the second mode, the first drum (204) and the second drum (214) are configured to rotate in response to longitudinal movement of the moving element (111), causing the first cable (201) and the second cable (211) to unwind from the first drum (204) and the second drum (214), respectively.
29. The instrument (100) as claimed in claim 28, wherein the second pulley (210) comprises a second torsion spring (213) coupled to the second drum (214) and wherein the first pulley (200) comprises a first torsion spring (203) coupled to the first drum (204), wherein the second torsion spring (213) and the first torsion spring (203) are configured to retract the second drum (214) and the first drum (204) to respective initial positions, causing the second cable (211) and the first cable (201) to rewind on the second drum (214) and the first drum (204), respectively.