AN IMPROVED DVDR MANUFACTURING SYSTEM ADAPTED TO OPTIMIZE USAGE OF CLIMATE UNIT CONNECTED THERETO AND A METHOD FOR OPTIMIZATION OF USAGE OF SUCH CLIMATE UNIT. FIELD OF THE INVENTION
The present invention relates in general to an improved DVDR manufacturing system adapted to optimize usage of climate unit connected thereto and in particular, to optimization of usage of climate unit, connected to a DVDR manufacturing system, during the manufacturing process of a DVDR. BACKGROUND OF THE INVENTION
To maintain controlled Air flow at Dye coater area, in DVDR application equipment climate unit is required to be connected to a DVDR manufacturing system , which is called Weiss unit.
Purpose of Weiss unit is to maintain air flow , temperature, Humidity at Dye coater as required, during the manufacturing process of a DVDR, namely, Airflow =1.0+/-0.1 Temp. =27.0+/-0.1 Humidity = 45 +/-1.0%
The above parameters and aspects are traditionally known and should be clear to persons skilled in the art.
In brief, the various steps, involved in the manufacturing process of DVDR, which are facilitated by connectivity to a climate unit are, filtration process, cooling process, heating, air movement and humidification. These processes are all traditionally known to persons skilled in the art, for example air filtration is done by simply filtering air through air filters, cooling is done by refrigerant system adapted for the purpose, heating is done with specially designed heaters and air movement and humidification are done with specially designed fans and humidifiers respectively, adapted for the purpose. So, ideally, connectivity of a DVDR manufacturing system, with a comprehensive climate unit, is to ensure accurate supply of air flow in the dyer coater area, which is the critical process station in CDR/DVDR, monitoring of
Temperature, Relative Humidity and consequently power consumption. The above requirements were hitherto achieved, by connecting two DVDR lines with one climate unit. However, this resulted in too many process related issues in dye-coating process and high Power Consumption and consequently, greater cost in maintaining Climate units and clean room space.
Hence there was a long felt need to design a DVDR manufacturing system having no process related issues in dye coating and involving low Power Consumption and low cost in maintaining Climate units and clean room space. All through out the specification a DVDR manufacturing system with at least one climate unit connected to it has been described, but it is implied that a DVDR manufacturing unit, may have more than one such climate unit in accordance with the invention connected to it, as may be required. OBJECTS OF THE INVENTION
It is a prime object of the present invention, to provide a DVDR manufacturing system having no process related issues in dye-coating and involving low power consumption and consequently, ensuring low cost in maintaining Climate units and clean room space.
It is another object of the present invention to provide a method for optimization of usage of climate unit, connected to a DVDR manufacturing system during the manufacturing process of a DVDR.
It is a further object of the present invention to reduce the overall production cost involved in DVDR manufacturing process.
It is a further object of the present invention to provide a climate unit, adapted to be connected to a DVDR manufacturing system, by at least four DVDR lines, whereby, total cost of production and process related issues in dye coating are reduced.
The above objects and other aspects of the invention will be clear from the description of preferred embodiments, described hereinafter, which are for the sake of understanding and not by any sort of limitation.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a DVDR manufacturing system having DVDR lines originating therefrom and including means for filtration process, cooling process, heating, air movement and humidification, said system further including at least one climate unit connected to it wherein said climate unit is connected to said DVDR manufacturing system by at least four DVDR lines and said climate unit is suitably adapted, for connectivity with at least four DVDR lines, whereby process related issues in the manufacturing process of DVDR are sorted out and low Power Consumption and low cost in maintaining Climate units and clean room space are ensured.
In accordance with preferred embodiments of the DVDR manufacturing system in accordance with the invention:
-the HUD of said climate unit is modified for connectivity with at least four DVDR lines and having one additional damper fixed in between to adjust the air flow requirement.
-five climate units are connected by twenty DVDR lines. The present invention also provides a method for optimization of usage of climate unit, connected to a DVDR manufacturing system during the manufacturing process of a DVDR, including adapting at least one said unit for connectivity with at least four DVDR lines and connecting at least one said climate unit to said system by at least four DVDR lines whereby, process related issues in the manufacturing process of DVDR are sorted out and low Power Consumption and low cost in maintaining Climate units and clean room space are ensured.
In accordance with preferred embodiments of the method for optimization of usage of climate unit, connected to a DVDR manufacturing system in accordance with the invention:
-the HUD of said climate unit is modified for connectivity to at least four DVDR lines , one additional damper is fixed in between to adjust the air flow requirement, the blower capacity of climate unit is increased and the damper of
all four lines is adjusted.
-including connecting five climate units to twenty DVDR lines.
The present invention also provides a climate unit adapted to be connected to a
DVDR manufacturing system as described hereinbefore.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The nature and scope of the present invention will be better understood from the
description of some preferred embodiments with reference to the accompanying
drawings, which are solely for the purpose of understanding and illustration, and
not by way of any sort of limitation. In the accompanying drawings,
Fig 1 illustrates a climate unit in accordance with the present invention.
Fig 2 illustrates a conventional manufacturing system having two DVDR lines
connected to one climate unit.
Fig 3 illustrates a DVDR manufacturing system in accordance with the invention
having at least four DVDR lines connected to one climate unit.
Figs 4(a)and (b) illustrate temperature data obtained from a climate unit
connected to two DVDR lines, as conventionally known.
Figs 5(a) and (b) illustrate humidity data obtained from a climate unit connected
to two DVDR lines, as conventionally known.
Figs 6(a) and (b) illustrate air flow data obtained from one climate unit connected to two DVDR lines, as conventionally known.
Figs 7(a) and (b) illustrate temperature data obtained from one climate unit connected to at least four DVDR lines in accordance with the present invention. Figs 8(a) and (b) illustrate humidity data obtained from one climate unit, connected to at least four DVDR lines, in accordance with the invention. Figs 9(a) and (b) illustrate air flow data obtained, from one climate unit with at least four DVDR lines.
Fig 10 illustrates probability plot of humidity data obtained from the improved arrangement in accordance with the invention.
Fig 11 illustrates probability plot of Air Flow data obtained from the improved arrangement in accordance with the invention. BRIEF DESCRIPTION OF THE INVENTION
As described hereinbefore, conventionally, a climate unit was connected to a DVDR manufacturing system utilizing two DVDR lines, for maintaining air flow , temperature, Humidity at Dye coater as required, during the manufacturing process of a DVDR. However, such connectivity resulted in too many process related issues in dye-coating process and high Power Consumption and consequently, greater cost in maintaining Climate units and clean room space. In accordance with the present invention, connectivity of a climate unit with the DVDR manufacturing system was facilitated utilizing at least four DVDR lines. This resulted in ameliorating the problems, in the existing arrangement as stated aforesaid.
To implement the invention, the HUD of the climate unit was modified for at least four DVDR lines (cooling air for 4 lines), one additional damper was fixed in between to adjust the air flow requirement, the blower capacity of climate unit was increased and the damper of all four lines was adjusted. As can be seen from the various accompanying figures, data pertaining to different parameters like air flow requirement, temperature, humidity and Power Consumption were obtained and projected, using the conventional connection of two DVDR lines with one climate unit in a DVDR manufacturing system and using the connection of at least four DVDR lines with one climate unit in a DVDR manufacturing system.
On comparison of the two sets of data, it can be clearly deciphered that on running at least four DVDR lines with one climate unit incorporating all modifications as above, there is marked improvement, in as much as there is hardly any process related issues in the dye-coating process and Power
Consumption is reduced.
The invention was implemented by first starting with running three DVDR lines with one climate unit, followed by close monitoring and finally switching over to the connection of at least four DVDR lines with one climate unit, in accordance with the present invention.
The advantageous results, obtained from the climate unit, connected to at least four DVD lines have been summarized, in a nutshell in the following table.

So, in conclusion at least four DVDR lines connected to a climate unit in a DVDR manufacturing system run smoothly, maintaining air-flow, temperature, Rh as per process requirement, thereby reducing the overall cost. Likewise, it is to be understood .that total 20 DVDR lines may run with 5 Climate units and so on. The present invention has been described with reference to some drawings and preferred embodiments, purely for the sake of understanding and not by way of
any limitation and the present invention includes all legitimate developments within the scope of what has been described hereinbefore and what has been claimed hereinafter.

WE CLAIM
1 .A DVDR manufacturing system having DVDR lines originating therefrom and including means for filtration process, cooling process, heating, air movement and humidification, said system further including at least one climate unit connected to it wherein said climate unit is connected to said DVDR manufacturing system by at least four DVDR lines and said climate unit is suitably adapted, for connectivity with at least four DVDR lines, whereby process related issues in the manufacturing process of DVDR are sorted out and low Power Consumption and low cost in maintaining Climate units and clean room space are ensured.
2.A DVDR manufacturing system as claimed in claim 1 wherein the HUD of said climate unit is modified for connectivity with at least four DVDR lines and having one additional damper fixed in between to adjust the air flow requirement. 3..A DVDR manufacturing system as claimed in any preceding claim comprising five climate units connected by twenty DVDR lines.
4. A method for optimization of usage of climate unit, connected to a DVDR manufacturing system during the manufacturing process of a DVDR, including adapting at least one said unit for connectivity with at least four DVDR lines and connecting at least one said climate unit to said system by at least four DVDR
•■HP
lines whereby, process related issues in the manufacturing process of DVDR are sorted out and low Power Consumption and low cost in maintaining Climate units and clean room space are ensured.
5. A method for optimization of usage of climate unit as claimed in claim 4 wherein the HUD of said climate unit is modified for connectivity to at least four DVDR lines , one additional damper is fixed in between to adjust the air flow requirement, the blower capacity of climate unit is increased and the damper of all four lines is adjusted.
6. A method for optimization of usage of climate unit as claimed in claim 5 including connecting five climate units to at least twenty DVDR lines.
7. A DVDR manufacturing system substantially as herein described, particularly with reference to the accompanying drawings.
8. A method for optimization of usage of climate , substantially as herein described.
9. A climate unit adapted to be connected to a DVDR manufacturing system as claimed in claims 1 to 3.