Plasma Coating Receptacle for Oxidation-Free Powder Transfer
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Solution Overview
Problem
The transfer of surfaces to and from coating equipment using plasma can be problematic due to material loss and oxidation, especially when dealing with light powders or oxygen-sensitive materials, and existing sealed transfer systems are cumbersome and time-consuming.
Innovation Solution
A method and system where the surface is coated within a receptacle that is brought to the coating equipment, using a holder to open and close the receptacle, applying plasma coating by pumping, injecting reaction gas, rotating, and generating plasma within the receptacle, allowing simultaneous or sequential performance of these steps, and removing the receptacle after coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sealed transfer system is used between the receptacle and the coating drum, then material loss and oxidation are prevented, but the system becomes complex and time-consuming to operate
Solution Approach 1:
The patent combines the transport function and coating function into a single integrated system. The receptacle that transports the surface is the same receptacle that serves as the coating chamber, eliminating the need for separate transfer mechanisms between different chambers. This merging of functions resolves the contradiction by maintaining reliability (through continuous sealed operation) while reducing device complexity (by eliminating intermediate transfer systems).
Solution Approach 2:
The receptacle is designed to perform multiple functions: it serves as both the transport container for bringing surfaces to the coating location and as the coating chamber itself. This multi-functionality eliminates the need for separate transfer drums and sealed transfer systems, thereby reducing operational complexity and time while maintaining the reliability of preventing material loss and oxidation through continuous sealing.
2Reliability
If the surface is transferred using a sealed transfer system, then material loss and oxidation are prevented, but the coating process becomes time-consuming
Solution Approach 1:
By merging the transport and coating operations into a single continuous process within the same receptacle, the patent eliminates the time required for intermediate transfer steps. The surface remains in the sealed receptacle throughout the entire process from transport to coating, eliminating transfer time while maintaining protection against material loss and oxidation.
Solution Approach 2:
The patent ensures continuous useful action by maintaining the surface in a sealed environment throughout the entire process without interruption. The receptacle remains sealed during transport, during the coating process, and during removal, eliminating any breaks where transfer operations would be required. This continuity prevents material loss and oxidation while significantly reducing the total time required compared to systems with intermediate transfer steps.
3Productivity
If the receptacle is used as both transport container and coating chamber, then transfer operations are eliminated, but the receptacle must be opened and closed during the process
Solution Approach 1:
The patent extracts the problematic intermediate transfer operation from the process by using the receptacle for both transport and coating. The only opening and closing that occurs is at the very beginning (before transport) and very end (after coating) of the process, removing the need for repeated opening and closing during intermediate transfers. This extraction of the transfer step resolves the contradiction by maintaining high productivity while minimizing the complexity of opening and closing operations to just two instances.
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
This approach eliminates the need for surface transfer, ensuring safe and reliable plasma coating without material loss or oxidation, while simplifying the process and reducing time and complexity.
Implementation Method 1
pumping gas out of the receptacle with a pumping system of the coating equipment
Implementation Method 2
generating a plasma inside the receptacle with an electrode setup of the coating equipment in order to coat the surface
Implementation Method 3
injecting a reaction gas in the receptacle with a gas injection system of the coating equipment
Data Source
AI summary
The present disclosure relates to a method for coating a surface with a coating equipment. The receptacle which was used for shipping the surface to be coated to the location of the coating equipment and will be used for shipping the coated surface outside the location is also used as a coating drum inside the coating equipment. The present disclosure also relates to a coating equipment suitable to accommodate the receptacle which was used for shipping the surface to be coated to the location of the coating equipment and will be used for shipping the coated surface outside the location.