Solid Electrolyte Membrane Re-tensioning for Metallic Coating
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Solution Overview
Problem
The existing method for forming metallic coatings using a solid electrolyte membrane can result in air entrainment between the membrane and the substrate, leading to non-uniform contact and the occurrence of spot and burnt deposits due to wrinkles in the membrane.
Innovation Solution
The method involves re-tensioning the solid electrolyte membrane with a constant tensile force to remove wrinkles, and using alternating current impedance measurements to determine if air is entrained, with subsequent etching if necessary to ensure proper contact and prevent deposits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the solid electrolyte membrane is pressed against the substrate to form a metallic coating, then the film formation efficiency is improved, but air may be entrained between the membrane and substrate causing spot and burnt deposits
Solution Approach 1:
The patent applies preliminary action by measuring the alternating current impedance before film formation to detect air entrapment. The imaginary component of the impedance is evaluated to determine contact quality, and if air is detected, the membrane is re-tensioned before proceeding with coating formation, thereby preventing defects without sacrificing efficiency
Solution Approach 2:
The patent implements feedback control by continuously monitoring the alternating current impedance during the process. The measured imaginary component provides real-time information about membrane-substrate contact quality, enabling dynamic adjustment of membrane tension to maintain optimal contact and prevent spot and burnt deposits
2Productivity
If the solid electrolyte membrane is reused for multiple film formations, then productivity is improved, but wrinkles occur in the membrane leading to air entrapment
Solution Approach 1:
The patent uses feedback control to monitor membrane condition during repeated use. By measuring the alternating current impedance and evaluating its imaginary component, the system detects when wrinkles cause air entrapment, then triggers re-tensioning to restore membrane flatness and contact uniformity, enabling continuous high-quality production
Solution Approach 2:
The patent applies self-service by using the alternating current impedance measurement to automatically detect membrane condition and trigger re-tensioning when needed. The system monitors its own state and performs corrective actions without external intervention, maintaining manufacturing precision throughout repeated use
3Measurement precision
If the imaginary component of alternating current impedance is used to detect air entrapment, then detection accuracy is improved, but additional measurement steps increase process complexity
Solution Approach 1:
The patent replaces complex visual inspection or contact-based detection methods with electrical impedance measurement. By measuring the alternating current impedance and analyzing its imaginary component, the system achieves accurate air entrapment detection through electrical properties rather than mechanical or optical means, simplifying the overall detection system
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 effectively suppresses the formation of spot and burnt deposits by ensuring uniform contact and removing oxides or contaminants, allowing for continuous and high-quality metallic coating formation on multiple substrates.
Implementation Method 1
a solid electrolyte membrane impregnated with metal ions between an anode and a substrate
Implementation Method 2
since a capacitance increases when air is entrained between the solid electrolyte membrane and the substrate, the imaginary component of the alternating current impedance decreases
Implementation Method 3
applying a voltage between the anode and the substrate in a state of pressing the substrate by the solid electrolyte membrane
Data Source
Figure 1A~1B
Figure 1C
Figure 2
AI summary
It is determined whether an imaginary component at a predetermined frequency of an alternating current impedance is equal to or more than a preliminarily set film-formable value or not. The metallic coating is formed in a state where the substrate is pressed by the solid electrolyte membrane when the imaginary component is equal to or more than the film-formable value in the determining. The metallic coating is formed in a state where the pressing of the substrate by the solid electrolyte membrane is released to separate the solid electrolyte membrane from the substrate, the solid electrolyte membrane is re-tensioned with a constant tensile force, and subsequently, the substrate is pressed by the re-tensioned solid electrolyte membrane when the imaginary component is smaller than the film-formable value in the determining.