Atmospheric Plasma Coating Device Relaxation Chamber
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Solution Overview
Problem
Existing corrosion protection methods for metals and metal alloys are inefficient, requiring multiple baths and high equipment costs, with bath-based processes being space-intensive and generating hazardous waste, and plasma jet methods having low deposition rates and inconsistent layer quality.
Innovation Solution
A non-vacuum coating device that uses plasma polymerization at atmospheric pressure, with a relaxation space to control plasma jet relaxation and precursor fragmentation, allowing for high-speed, high-quality corrosion protection layer application on various metal surfaces without the need for multiple baths or complex equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bath-based corrosion protection processes are used, then corrosion protection layers can be applied to metals, but the process requires large space, high chemical costs, and generates hazardous waste
Solution Approach 1:
The patent replaces the wet-chemical bath system with a plasma-based physical-chemical process. The plasma jet delivers reactive species that deposit corrosion protection layers without requiring liquid chemicals, thereby eliminating chemical storage, monitoring, and waste treatment infrastructure while maintaining protective function
Solution Approach 2:
The invention uses a plasma jet (gas phase) instead of liquid baths to deliver coating materials. The plasma-containing gas is directed onto the metal surface, allowing corrosion protection without the space and waste issues associated with liquid chemical baths
2Reliability
If different metals are treated with bath-based processes, then each metal can receive appropriate corrosion protection, but multiple incompatible baths and sequences are required
Solution Approach 1:
The plasma jet system serves multiple functions: it activates diverse metal surfaces through plasma treatment and simultaneously deposits corrosion protection layers. The process parameters (gas composition, power, flow rate) can be adjusted to handle different metals, making a single device versatile for aluminum, steel, copper, and their alloys without requiring separate bath systems
3Ease of manufacture
If plasma jet coating is used, then corrosion protection layers can be applied without baths, but the layer deposition rate is low at 0.4 μm/sec
Solution Approach 1:
The invention optimizes plasma process parameters including increasing plasma power, adjusting gas flow rates, and controlling the distance between the plasma jet and substrate. These parameter changes enhance the deposition rate while maintaining layer quality, allowing faster production without requiring a return to bath-based processes
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 solution enables durable, well-adhering corrosion protection layers to be applied efficiently and consistently across different metal surfaces, avoiding the drawbacks of traditional methods by simplifying setup and reducing waste, while achieving superior corrosion protection effects.
Implementation Method 1
A plasma jet is generated, with a second gas phase being introduced into a plasma-activated first gas phase
Implementation Method 2
During their flight to a surface to be coated, the components of the second gas phase should be converted into particle species suitable for layer deposition
Data Source
Figure 1
Figure 2a~2c
AI summary
The present invention relates to a coating device, comprising a plasma generating chamber with a housing for the collection of the plasma produced therein, a nozzle duct formed by the housing with an outlet from the housing, an electrode arranged in the nozzle duct, an ionized gas inlet for the inlet of a gas to be ionized in the plasma generating chamber with a volume flow of 15 to 50 l/min, a relaxation chamber, comprising a precursor feed, being spaced 1 to 25 mm, preferably 1 to 7 mm from the outlet of the housing of the plasma generating chamber.