Nanocomposite Roller Coating for Heat-Resistant Electrode Manufacturing
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Solution Overview
Problem
Existing coatings for rollers in secondary battery manufacturing facilities, such as diamond-like carbon (DLC), are inadequate for large rollers due to heat weakness and non-uniform application, failing to provide heat resistance, non-stick properties, durability, chemical resistance, and low friction.
Innovation Solution
A ternary nanocomposite coating material comprising C—F—Si or C—F—H is applied using a CVD process with a dense plasma formation and a Cr-based buffer layer, enhanced by a magnetic field and high bias voltage, to achieve uniform coating on large areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If diamond-like carbon (DLC) coating is applied to rollers, then non-stick properties are improved, but heat resistance deteriorates
Solution Approach 1:
The patent applies a composite coating structure consisting of a Cr-based buffer layer combined with a PVD or CVD coating layer (such as DLC, TiN, or other ceramic coatings). This composite structure allows the buffer layer to provide thermal stability and adhesion to the substrate, while the outer coating layer provides non-stick properties. The multi-layer composite approach resolves the contradiction by combining materials with complementary properties.
2Object-affected harmful factors
If coating is applied to large rollers (up to 5 tons), then non-stick properties are improved, but coating uniformity deteriorates
Solution Approach 1:
The Cr-based buffer layer serves as an intermediary between the roller substrate and the outer coating layer. This buffer layer improves adhesion and provides a uniform intermediate surface that facilitates more uniform deposition of the outer coating, even on large rollers weighing up to 5 tons. The buffer layer acts as a mediator that compensates for surface irregularities and promotes consistent coating application across large areas.
Solution Approach 2:
The patent employs parameter optimization in the PVD or CVD coating process, including controlling deposition rate, substrate temperature, and coating thickness parameters. By carefully adjusting these parameters, the process achieves uniform coating deposition on large roller surfaces despite their size and weight. The controlled parameter changes ensure consistent coating quality across the entire roller surface.
3Ease of manufacture
If conventional coating materials are used, then ease of manufacture is improved, but durability deteriorates
Solution Approach 1:
The patent uses a composite coating system with a Cr-based buffer layer and an outer functional coating layer. While the multi-layer structure requires more complex manufacturing than single-layer coatings, each layer serves a specific function that collectively enhances durability. The buffer layer provides adhesion and corrosion resistance, while the outer layer provides wear resistance and non-stick properties, resulting in superior overall durability 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 exhibits high hardness, low friction, excellent adhesion resistance, and chemical resistance, preventing static electricity and arcing, thus improving productivity and product quality.
Implementation Method 1
a dense plasma must be formed, so permanent magnets or electromagnets are arranged in the ion source to form a magnetic field, so that the plasma is densely packed in a predetermined space
Implementation Method 2
a raw material supply feeding C, F, Si or C, F, H to said ion source as raw material
Implementation Method 3
permanent magnets or electromagnets are arranged in the ion source to form a magnetic field, so that the plasma is densely packed in a predetermined space
Implementation Method 4
a ternary nanocomposite coating material comprising C—F—Si or C—F—H is coated on a base material by a CVD process
Implementation Method 5
a cylinder sputtering device including a Cr cylinder target is mounted in said chamber so that a Cr-based buffer layer is formed on the surface of the base material
Data Source
AI summary
It is an object to provide a coating material having heat resistance, adhesion resistance, durability, chemical resistance, low friction, and releaseability applied to a base material, and to provide a manufacturing method and manufacturing system for such a coating material. A ternary nanocoposite coating material comprising C—F—H or C—F—Si applied to a base material is disclosed.