Solid Electrolyte Membrane Concave Portion for Coating Edge Clarity
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Solution Overview
Problem
Existing metal coating techniques, such as electroless plating and PVD methods, face challenges like the need for washing processes, internal stress in coatings, and limitations in coating thickness, as well as unclear edge portions due to ion diffusion in solid electrolyte membranes.
Innovation Solution
A coating forming device with a solid electrolyte membrane having a contact surface and a concave portion, where the contact surface forms the metal coating while the concave portion avoids non-coating regions, allowing precise deposition of metal ions on the substrate with controlled pressure and water repellency to enhance coating quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a solid electrolyte membrane is used to form metal coating, then metal ions can be deposited on the substrate, but metal ions diffuse into the non-coating region causing unclear edge portions
Solution Approach 1:
The solid electrolyte membrane is divided into a contact surface region and a non-contact region by forming a concave portion. The contact surface contacts only the coating-forming region of the substrate, while the non-contact region (concave portion) prevents metal ion diffusion to the non-coating region, thereby achieving clear coating edges.
Solution Approach 2:
Different regions of the solid electrolyte membrane are given different functions: the contact surface region allows metal ion passage for coating formation, while the non-contact region (concave portion) prevents ion diffusion. This local differentiation of function resolves the edge clarity issue.
2Productivity
If the solid electrolyte membrane contacts the entire substrate surface, then coating can be formed, but metal ions deposit on non-coating regions reducing manufacturing precision
Solution Approach 1:
The membrane surface is segmented into contact and non-contact regions, allowing selective coating only on the coating-forming region while maintaining efficient ion transport through the contact surface.
Solution Approach 2:
The concave portion extracts or removes the membrane material from the non-coating region area, preventing unwanted deposition while preserving coating efficiency on the target region.
3Ease of manufacture
If electroless plating is used to form metal coating, then coating can be formed, but washing process and waste liquid treatment are required
Solution Approach 1:
The electrochemical deposition method replaces the chemical electroless plating process, eliminating the need for washing and waste treatment while achieving comparable coating results.
4Manufacturing precision
If PVD method such as sputtering is used, then metal coating can be formed, but internal stress is generated limiting coating thickness
Solution Approach 1:
The deposition parameters are changed by using an electrochemical method instead of PVD, allowing thicker coatings to be formed without the internal stress limitations that constrain sputtering-based methods.
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 enables the formation of metal coatings with clear, conspicuous edge portions and complex shapes at a low cost, while maintaining uniform pressure and preventing excessive membrane protrusion, thus improving coating efficiency and clarity.
Implementation Method 1
a technique of forming a metal coating by plating such as electroless plating
Implementation Method 2
forming a metal coating by making the solid electrolyte membrane containing metal ions into contact with the surface of the substrate and causing the power supply to apply a voltage between the anode and the cathode (substrate) to deposit the metal ions on the surface of the metal substrate
Implementation Method 3
a solid electrolyte membrane that is disposed between the anode and a substrate (cathode)... a solid electrolyte membrane which contains metal ions
Implementation Method 4
metal of the coating-forming surface has a lower oxygen overvoltage than metal of the non-coating-forming surface. Therefore, the reactivity of deposition of metal ions on metal in a region between the coating-forming surface of the anode and the substrate can increase
Data Source
AI summary
A coating forming device for forming a metal coating on a surface of a substrate includes: an anode; a power supply; and a solid electrolyte membrane disposed between the anode and the substrate and contains metal ions. The solid electrolyte membrane includes: a contact surface that is a region contacting a coating-forming region where the metal coating is formed; and a concave portion recessed relative to the contact surface such that, when the contact surface contacts the coating-forming region, the solid electrolyte membrane is not in contact with a portion of the surface of the substrate excluding the coating-forming region. The metal ions are reduced to form the metal coating on the coating-forming region by the power supply applying a voltage between the anode and the substrate.