Surface-Modified Ceramic Thermal Spray Powder for Fine-Particle Flow
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Solution Overview
Problem
Existing thermal spray coating methods using ceramic powders face challenges with fluidity issues due to particle agglomeration, leading to reduced process efficiency and non-uniform coatings, especially when using particles smaller than 30 μm, and current surface treatments like plasma or stearic acid leave residues or require high energy and cannot maintain fluidity at room temperature.
Innovation Solution
A ceramic thermal spray coating material is developed with a surface-modified ceramic granule powder using stearic acid with an ammonium group, applied through methods like spray drying or fluidized bed drying, to enhance fluidity and minimize residue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If particle size is reduced to 30 μm or less to achieve smooth coating, then coating uniformity is improved, but surface energy between particles increases causing agglomeration and reduced fluidity
Solution Approach 1:
The patent introduces a surface treatment using ammonium stearate as an intermediary substance to reduce the surface energy between ceramic particles. This mediator prevents direct particle-particle interaction that causes agglomeration, thereby maintaining fluidity while using fine particles for smooth coating.
Solution Approach 2:
The patent changes the surface energy parameter of ceramic particles by applying ammonium stearate coating. This parameter change reduces inter-particle attraction forces, preventing agglomeration and maintaining fluidity of fine particles during the coating process.
2Ease of operation
If plasma treatment is used to improve fluidity, then particle agglomeration is reduced, but process installation cost and energy consumption increase
Solution Approach 1:
The patent replaces expensive and energy-intensive plasma treatment with a cheaper chemical coating method using ammonium stearate. This disposable chemical coating achieves the same fluidity improvement without requiring high-energy plasma equipment or excessive energy consumption.
Solution Approach 2:
The patent substitutes the mechanical/physical plasma treatment process with a chemical coating process. Instead of using high-energy plasma to modify particle surfaces, the patent uses chemical adsorption of ammonium stearate to achieve surface energy reduction and improved fluidity.
3Ease of operation
If general stearic acid is coated to improve fluidity, then particle agglomeration is reduced, but uniform coating is impossible and residue remains at 60° C. or higher
Solution Approach 1:
The patent changes the chemical structure of the stearic acid derivative by introducing an ammonium group. This parameter change in molecular structure enables the coating to remain uniform and residue-free at elevated temperatures, overcoming the limitations of general stearic acid.
Solution Approach 2:
The patent uses a composite approach by combining ceramic particles with ammonium stearate coating. This composite structure provides both the ceramic functionality and the fluidity-enhancing properties of the ammonium stearate, while the specific chemical structure prevents residue formation at high temperatures.
4Manufacturing precision
If particle size is reduced to achieve high density coating, then coating density is improved, but process speed decreases and conveying pipe blockage occurs
Solution Approach 1:
The patent uses ammonium stearate as an intermediary to reduce inter-particle friction and agglomeration. This allows fine particles to flow smoothly through conveying pipes at high speeds without blockage, while still achieving high-density coating due to the small particle size.
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 provides improved fluidity and uniform coating with reduced agglomeration, maintaining process efficiency and enabling high-density, smooth coatings without the need for high-energy treatments, and ensures minimal residue formation.
Implementation Method 1
an organic compound modified on a surface of the ceramic granule powder
Implementation Method 2
Thermal spray coating using ceramic powders of single or composite materials
Implementation Method 3
applied through methods like spray drying or fluidized bed drying
Data Source
AI summary
A ceramic thermal spray coating material and a method of preparing a ceramic thermal spray coating material are disclosed. The ceramic thermal spray coating material comprises a ceramic granule powder and an organic compound containing stearic acid having an ammonium group, which is modified on the surface of the ceramic granule powder. Further, the method includes: preparing ceramic granule powders; adding stearic acid having an ammonium group and the ceramic granule powders to a first solvent to prepare a first mixed solution; evaporating the first solvent from the first mixed solution; and modifying a surface of the ceramic granule powders with an organic compound by evaporating the first solvent.