Rolling Sphere Coating Tracks for Uniform Deposition

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Solution Overview

Problem

Conventional methods for coating spherical substrates in a rolling manner suffer from issues such as substrate-substrate interaction, contamination, and non-uniformity due to changing positions during deposition, leading to material wear and coating defects.

Innovation Solution

A conical dish-like element with spaced apart track elements and a planar coating table with rotationally supported rods are used to support rolling elements, maintaining constant longitudinal positions and preventing contact, while channels and randomizing features drain contaminants and control depositing species flux.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional dish-shaped or straight-walled pans are used to support rolling spheres, then the spheres can be coated during rolling motion, but the spheres touch and collide leading to material wear and coating contamination

Engineering Contradiction:

Improvecoating efficiencyVSAvoidcoating contamination

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The pan is segmented into multiple discrete track elements spaced apart from each other. These track elements individually support the rolling spheres, preventing direct contact between adjacent spheres while maintaining controlled rolling motion for uniform coating application.

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If spheres are allowed to roll freely in conventional pans, then coating can be applied during motion, but the changing position of spheres prevents collimation of depositing species flux

Engineering Contradiction:

Improvecoating process simplicityVSAvoidcoating uniformity

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

Track elements serve as intermediaries between the pan surface and the rolling spheres. These tracks guide and constrain the spheres along predetermined paths, ensuring consistent positioning and motion patterns that enable precise control of coating deposition while maintaining rolling motion.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If conventional pans are used for rolling spheres, then the coating process can proceed, but particulates are trapped in the rolling region leading to coating defects

Engineering Contradiction:

Improvecoating throughputVSAvoidcoating quality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The harmful particulates are extracted or removed from the coating region by allowing them to pass through the spaces between the spaced-apart track elements. This design actively eliminates contamination sources rather than merely containing them, ensuring cleaner coating deposition.

Inventive Principle:

Principle #2Taking out (Extraction)

4Quantity of substance

If multiple spheres are rolled in conventional pans, then batch coating is achieved, but substrate-substrate interaction causes material wear

Engineering Contradiction:

Improvenumber of coated spheresVSAvoidmaterial integrity

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

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 ensures uniform coating by preventing substrate contact and contamination, allowing for scalable and cost-effective coating of multiple spherical objects with reduced defects.

Implementation Method 1

The coating subsystem generates a plasma made up of an electrically excited gas (e.g., argon working gas and precursor molecules) that coats the rolling or spherical substrates

Methodology Applied

Scientific EffectPlasma: Plasma

Implementation Method 2

Conventionally, spherical substrates have been coated by vapor deposition techniques

Methodology Applied

Scientific EffectVapor deposition: Physical Vapour Deposition

Data Source

PatentUS20250207240A1Systems and methods for uniform coating of rolling spheres

Publication Date: 2025.06.26 LAWRENCE LIVERMORE NAT SECURITY LLC

AI summary

The present disclosure relates to an apparatus for coating rollable elements. The apparatus may have a coating subsystem for generating a coating material, and a conical, dish-like element or an array of rotating rods for supporting the rolling elements thereon for rolling motion during a coating process during which the rolling elements receive the coating material. The conical dish-like element has a plurality of spaced apart track elements for supporting the rolling elements thereon. The array of rods has a plurality of spaced apart grooves for supporting the rolling elements. The openings between track elements or rotating rods allow for particulates and/or contaminants to pass during the coating process.