High-Entropy Roller Coating for Durable Anti-Adhesion Surfaces
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Solution Overview
Problem
Existing technologies struggle to provide a coating material for rollers used in secondary battery manufacturing that offers high durability, anti-adhesion properties, and excellent surface smoothness while maintaining high purity of electrode materials, without the environmental pollution and low durability issues associated with current wet plating methods.
Innovation Solution
A high-entropy alloy coating material composed of Ni—Co—Cr—Si, applied in multiple layers with varying nitrogen or carbon content, is used to form a durable, anti-adhesive, and high-purity coating on rollers, utilizing a dry hybrid plasma nano-composite process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wet plating technology is used to coat rollers, then the coating process is simple, but the coating has low density, low durability, and generates many pores and residual substances
Solution Approach 1:
The patent replaces the chemical wet plating process with a physical vapor deposition process using a sputtering device. This substitution eliminates the need for chemical solutions while achieving high-density, pore-free coatings with superior durability. The sputtering process deposits material physically through plasma-induced ejection, forming a dense coating structure without the harmful chemical residues associated with wet plating.
Solution Approach 2:
The patent employs an inert atmosphere (argon gas) within the vacuum chamber during the sputtering process. This inert environment prevents oxidation and contamination of the coating material during deposition, ensuring high-purity, dense coatings without pores or residual substances. The vacuum conditions also enable precise control over coating thickness and composition.
2Ease of manufacture
If wet plating technology is used to coat rollers, then the coating process is simple, but the coating has low density and generates many pores
Solution Approach 1:
The patent replaces the chemical wet plating process with a physical vapor deposition process using a sputtering device. This substitution eliminates the need for chemical solutions while achieving high-density, pore-free coatings with superior durability. The sputtering process deposits material physically through plasma-induced ejection, forming a dense coating structure without the harmful chemical residues associated with wet plating.
Solution Approach 2:
The patent employs an inert atmosphere (argon gas) within the vacuum chamber during the sputtering process. This inert environment prevents oxidation and contamination of the coating material during deposition, ensuring high-purity, dense coatings without pores or residual substances. The vacuum conditions also enable precise control over coating thickness and composition.
3Ease of manufacture
If conventional coating materials are used on rollers, then the roller can be manufactured, but the roller lifespan is significantly reduced due to harsh conditions
Solution Approach 1:
The patent applies a multi-layer composite coating structure consisting of a buffer layer and a functional layer. The buffer layer (containing elements like Ni, Co, Cr, Si) provides adhesion and corrosion resistance, while the functional layer (containing nitrogen or carbon) provides low friction and wear resistance. This composite structure significantly extends roller lifespan under harsh conditions compared to conventional single-layer coatings.
Solution Approach 2:
The patent modifies the coating material composition by incorporating specific elements (Ni, Co, Cr, Si) in controlled proportions and adjusting the nitrogen or carbon content in the functional layer. These parameter changes optimize the coating's mechanical properties, hardness, and friction characteristics, thereby extending roller lifespan under harsh manufacturing conditions.
4Reliability
If the coating material is applied to ensure anti-adhesion properties, then adhesion issues with electrode materials are reduced, but the surface smoothness must be maintained to prevent contamination
Solution Approach 1:
The patent applies a multi-layer composite coating structure consisting of a buffer layer and a functional layer. The buffer layer (containing elements like Ni, Co, Cr, Si) provides adhesion and corrosion resistance, while the functional layer (containing nitrogen or carbon) provides low friction and wear resistance. This composite structure significantly extends roller lifespan under harsh conditions compared to conventional single-layer coatings.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coating enhances roller durability, thermal stability, and anti-adhesion properties, maintaining electrode purity and extending roller lifespan under harsh conditions, with improved mechanical properties and reduced friction.
Implementation Method 1
a sputter source, and an ion source, in this system, a high-entropy alloy target containing Ni—Co—Cr—Si is mounted onto the sputter source
Implementation Method 2
by applying power to both the sputter source and the ion source, a roller surface coating material composed of Ni—Co—Cr—Si—N is formed
Data Source
AI summary
The objective of the present invention is to design a novel coating material applied to the surface of industrial rollers used in the manufacturing process of secondary batteries and to provide a method for forming the coating material. In accordance with this objective, the present invention provides a roller surface coating material composed of Ni—Co—Cr—Si—N, utilizing a high-entropy alloy target containing Ni—Co—Cr—Si.