Multi-Walled Steel Tube Plasma Coating Without Nickel Interlayer
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Solution Overview
Problem
Existing methods for producing multi-walled pipes using electroplating with cyanide-containing electrolytes are complex, costly, and environmentally and health hazardous, requiring a nickel layer between steel and copper layers for adequate adhesion.
Innovation Solution
Applying a solder layer, preferably copper, directly to a steel strip using plasma coating without the need for a nickel intermediate layer, simplifying the process and eliminating toxic cyanides and hazardous materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electroplating with cyanide-containing electrolyte baths is used to apply the solder layer, then adequate adhesion of the solder layer to the steel layer can be achieved, but the process becomes complex, costly, and environmentally and health hazardous
Solution Approach 1:
The invention extracts and eliminates the harmful cyanide-containing electrolyte bath from the electroplating process, replacing it with a plasma coating process that achieves adequate adhesion without toxic substances. This resolves the contradiction by maintaining reliability through plasma treatment while removing the complex and hazardous electroplating process.
Solution Approach 2:
The invention replaces the chemical-electrical process of electroplating with a physical plasma coating process. This substitution eliminates the need for cyanide-containing electrolytes and complex galvanic processes while achieving comparable or superior adhesion results, thereby reducing process complexity and environmental hazards.
2Reliability
If a nickel layer is interposed between the steel layer and the copper layer to apply the copper layer, then adequate adhesion can be achieved, but the process becomes more complex and costly, and harmful nickel is used
Solution Approach 1:
The invention extracts and eliminates the intermediate nickel layer from the multi-layer structure. By using plasma coating directly on the steel layer, the process achieves adequate adhesion without requiring the additional nickel layer, thereby simplifying the process and removing harmful nickel from the final product.
Solution Approach 2:
The plasma coating process acts as an intermediary mechanism that enables direct bonding between the steel layer and copper solder layer without requiring a nickel intermediate layer. The plasma treatment modifies the steel surface to achieve adequate adhesion, replacing the traditional nickel mediator with a process-based solution.
3Ease of manufacture
If cyanide-containing electrolyte baths are used for electroplating, then the solder layer can be applied, but environmental and health disadvantages arise and disposal of residues is problematic
Solution Approach 1:
The invention replaces the chemical-electrical electroplating system with a physical plasma coating system. This substitution eliminates cyanide-containing electrolyte baths entirely, removing environmental and health hazards while maintaining the capability to apply solder layers effectively. The plasma process uses ionized gas instead of toxic liquids.
Solution Approach 2:
The invention converts the harmful cyanide-based electroplating process into a beneficial plasma coating process. By using plasma treatment, the process achieves effective coating application while eliminating toxic residues, turning a harmful manufacturing method into an environmentally friendly one.
4Ease of manufacture
If the galvanic process is used to apply the solder layer, then the coating can be applied, but the process is complex and expensive requiring complex adjustments to process parameters
Solution Approach 1:
The invention replaces the complex galvanic electroplating process with a simpler plasma coating process. The plasma process requires fewer complex parameter adjustments and eliminates the need for electrolyte bath preparation, drying, and cleaning steps, thereby reducing overall process complexity while maintaining coating quality.
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 method allows for simple, cost-effective production of multi-walled pipes with improved adhesion and reduced environmental and health risks, using less material and energy, and achieving high-quality, homogeneous coatings.
Implementation Method 1
the solder layer is applied to the steel layer by plasma coating
Implementation Method 2
the plasma coating is carried out as a physical vapor deposition
Implementation Method 3
the cleaning of the surface of the steel strip or the steel layer to be coated is cleaned by means of plasma treatment
Data Source
Figure 1~2
Figure 3
AI summary
A method for producing multi-walled tubes, wherein a metal strip is rolled up to form the multi-walled tube. The metal strip has at least one steel layer, and at least one solder layer is applied to the steel layer. The solder layer consists at least partially of metal. According to the invention, the solder layer is applied to the steel layer by plasma coating.