Texturized Thin Film Coating for Wear-Resistant Non-Smooth Surfaces

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Solution Overview

Problem

Current coating processes fail to maintain the underlying surface texture or profile of non-smooth surfaces, leading to degradation and inadequate wear resistance, particularly in applications like embossing rolls where texturing is crucial for lubrication and material processing.

Innovation Solution

A thin and texturized film is created using a liquid feedstock of particulates no larger than 5 microns, fed through an additive overlaying device, which generates a molten effluent that conforms to the non-smooth surface pattern, ensuring uniform coverage and maintaining the original texture while providing wear resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional coating processes are used, then wear resistance is improved, but the underlying surface texture is degraded or lost

Engineering Contradiction:

Improvewear resistanceVSAvoidsurface texture preservation

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention changes the particle size parameter of the coating material to less than 5 microns, which allows the coating to conform to the underlying surface texture while maintaining uniform thickness. This parameter change enables both wear resistance and texture preservation to be achieved simultaneously

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention applies a thin coating layer that is sufficient to provide wear resistance but thin enough to preserve the underlying surface texture. The coating thickness is controlled to be uniform and conform to the substrate texture, avoiding excessive coating that would mask the texture

Inventive Principle:

Principle #16Partial or excessive action

2Reliability

If hard chrome plating is used, then wear resistance is improved, but harmful chemicals (hexavalent chromium) are introduced

Engineering Contradiction:

Improvewear resistanceVSAvoidhexavalent chromium exposure

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention replaces harmful hexavalent chromium-based hard chrome plating with a particulate coating process that achieves comparable or superior wear resistance without the harmful chemicals. The particulate coating method converts a potentially harmful process into a beneficial alternative that maintains performance while eliminating toxicity

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention changes the material composition parameter from hexavalent chromium to alternative particulate materials that provide equivalent wear resistance without the harmful chemical properties, thereby eliminating the harmful factors while maintaining the functional benefit

Inventive Principle:

Principle #35Parameter changes

3Reliability

If thick coating is applied, then wear resistance is improved, but uniform coverage and texture retention are degraded

Engineering Contradiction:

Improvewear resistanceVSAvoiduniform coverage

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The invention changes the particle size parameter to less than 5 microns, which enables the coating material to flow and conform to the underlying surface texture uniformly. This fine particle size allows thick coating application while maintaining uniform coverage and preserving the substrate texture, avoiding the non-uniform thickness and texture loss associated with conventional coating methods

Inventive Principle:

Principle #35Parameter changes

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 achieves uniform coverage and enhanced wear resistance without degrading the surface texture, with film thickness ranging from 5 to 25 microns, maintaining or improving wear resistance comparable to hard chrome plating while avoiding harmful chemicals like hexavalent chromium.

Implementation Method 1

said textured, thin film derived from a liquid feedstock of particulates fed through an additive overlaying device

Methodology Applied

Scientific EffectAdditive overlaying: Deposition (physical)

Implementation Method 2

providing an additive overlaying device, said additive overlaying device comprising a combustion chamber and a nozzle; generating a hot gas effluent

Methodology Applied

Scientific EffectCombustion heating: Combustion

Data Source

PatentUS11479841B2Thin and texturized films having fully uniform coverage of a non-smooth surface derived from an additive overlaying process

Publication Date: 2022.10.25 PRAXAIR ST TECHNOLOGY INC

AI summary

This invention relates to a thin and texturized film that can be applied onto a non-smooth surface to improve hardness, corrosion resistance and wear resistance properties of the surface while maintaining the underlying profile of the non-smooth surface. An additive overlaying process can be employed to produce the thin and texturized film on the non-smooth surfaces without substantial alteration or degradation of the underlying surface texture or profile of the non-smooth surfaces so as to sufficiently preserve the underlying surface texture or profile. The thin and texturized film fully covers the non-smooth in a uniform manner and maintains the surface profile.