Plasma-Enhanced Nozzle Unit for Cold Spray Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Cold spray coating methods face inefficiencies due to decreased gas velocity near the inner lateral wall of nozzles, leading to lower momentum of powder particles, resulting in poor coating quality and longer coating layer formation times.
Innovation Solution
A nozzle unit with a dielectric material and a plasma source comprising a power electrode and a ground electrode, strategically positioned to generate plasma and maintain flow velocity, preventing velocity decrease and enhancing energy efficiency, thereby improving coating quality and reducing formation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cold spray coating is performed using conventional nozzle without plasma source, then the coating process is simple, but the gas flow velocity decreases near the inner lateral wall causing poor coating quality and long formation time
Solution Approach 1:
The patent replaces the conventional mechanical cold spray system with a plasma-enhanced system. A plasma source generates plasma that interacts with the coating material particles, using plasma energy instead of purely mechanical gas pressure to accelerate and deposit particles, thereby improving coating quality and reducing formation time
Solution Approach 2:
The patent changes the physical state and energy parameters of the coating process by introducing plasma. The plasma source alters the temperature, ionization state, and energy distribution of the gas and particles, transforming the coating mechanism from cold mechanical spray to plasma-enhanced deposition, which resolves the velocity and quality issues
2Speed
If gas pressure is increased to maintain flow velocity near inner lateral wall, then flow velocity is maintained, but energy efficiency decreases
Solution Approach 1:
The patent replaces mechanical pressure-based velocity maintenance with plasma-based energy input. Instead of increasing gas pressure to maintain velocity, the plasma source provides energy directly to the particles and gas, maintaining flow velocity through plasma heating and ionization rather than mechanical compression, thereby improving energy efficiency
3Reliability
If powder particles move along inner lateral wall with low velocity, then particles experience elastic collision causing voids and material loss, but increasing gas pressure to fix this reduces energy efficiency
Solution Approach 1:
The patent replaces mechanical velocity-based particle delivery with plasma-enhanced particle acceleration. The plasma source ionizes and accelerates particles through electromagnetic fields, ensuring particles maintain sufficient velocity even near the inner lateral wall, preventing elastic collisions and void formation without requiring increased gas pressure
Solution Approach 2:
The patent changes the energy state of particles from neutral to ionized through plasma treatment. This parameter change in electrical charge and energy state allows particles to be controlled and accelerated differently, preventing the elastic collision issue that plagues conventional cold spray near wall regions
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 effectively maintains flow velocity, increases energy efficiency, minimizes poor coating issues, and enables faster formation of thicker coating layers by accelerating plasma ions towards the spray hole, eliminating the need for additional pressure and preventing arcing.
Implementation Method 1
a plasma source for generating plasma from the fluid which flows to an area adjacent to inner lateral surface of the dielectric unit
Implementation Method 2
The plasma source comprises: a power electrode applying a power; and a ground electrode to be grounded
Implementation Method 3
a dielectric unit provided with a dielectric material
Data Source
AI summary
An embodiment includes a coating apparatus comprising: a support unit for supporting a coating object; and a spray assembly for spraying a fluid which includes a coating material to be coated by the coating object supported on the support unit. The spray assembly comprises: a nozzle unit where the fluid is sprayed; and a fluid supply unit for supplying the fluid to the nozzle unit. The nozzle unit comprises: a body including a passageway for the fluid therein and a dielectric unit provided with a dielectric material; and a plasma source for generating plasma from the fluid which flows to an area adjacent to inner lateral surface of the dielectric unit. The plasma source comprises: a power electrode applying a power; and a ground electrode to be grounded.