Water Fitting Coating with Nickel-Phosphorus Alloy and Gas Phase Deposition
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Solution Overview
Problem
Existing methods for producing water fitting components using galvanically or electrolytically applied chromium layers are resource-intensive and environmentally harmful due to waste water contamination and the use of hazardous SVHC compounds, while lacking in corrosion inhibition and decorative functionality.
Innovation Solution
A multi-layer coating system for water fitting components is developed, where a nickel-phosphorus alloy layer with a phosphorus mass fraction of at least 8% is applied using galvanic or electrolytic methods, followed by a gas phase deposition layer, eliminating the need for chromium plating and enhancing corrosion resistance and decorative properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If galvanic or electrolytic chromium plating is used, then corrosion protection is improved, but waste water contamination and environmental harm worsen
Solution Approach 1:
The patent extracts and eliminates the chromium plating process from the coating system, replacing it with a nickel-phosphorus alloy layer combined with PVD or DLC layers. This removes the source of chromium waste water contamination while maintaining the protective function through alternative materials that do not generate harmful waste water.
Solution Approach 2:
The patent changes the chemical composition parameters of the coating system by specifying a nickel-phosphorus alloy with at least 8% phosphorus content, which provides equivalent or superior corrosion protection compared to chromium plating without generating harmful waste water, thus resolving the contradiction between protection and environmental harm.
2Reliability
If galvanic or electrolytic chromium plating is used, then corrosion protection is improved, but use of hazardous SVHC compounds worsens
Solution Approach 1:
The patent removes the chromium plating process that requires hazardous SVHC compounds (such as chromium(VI) compounds and boric acid) and replaces it with galvanic or electrolytic nickel-phosphorus alloy plating followed by PVD or DLC coating, eliminating the need for hazardous substances while maintaining corrosion protection.
Solution Approach 2:
The patent employs a multi-layer coating system where the PVD or DLC layer serves as a protective top layer that can be applied relatively thinly (1-10 μm) over the nickel-phosphorus alloy base layer, providing durable corrosion protection without requiring hazardous SVHC compounds used in traditional chromium plating.
3Illumination intensity
If chromium layer is used between nickel-phosphorus alloy and PVD/DLC layer, then decorative appearance is improved, but resource consumption worsens
Solution Approach 1:
The patent extracts the chromium intermediate layer from the coating system and replaces it with a direct bond between the nickel-phosphorus alloy layer and the PVD or DLC layer. The PVD or DLC layer itself provides the decorative appearance (metallic, colored, or structured surfaces) without requiring chromium, thereby reducing resource consumption and waste water treatment requirements.
Solution Approach 2:
The patent creates a composite multi-layer coating system consisting of a nickel-phosphorus alloy layer (with at least 8% phosphorus) combined with a PVD or DLC layer. This composite structure achieves both decorative appearance and functional protection without the need for chromium, reducing resource consumption compared to traditional chromium-based multi-layer systems.
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 a resource-saving, environmentally friendly coating that effectively prevents corrosion and maintains decorative appearance, reducing waste water treatment costs and environmental impact without compromising corrosion protection or aesthetic appeal.
Implementation Method 1
The layer with the nickel-phosphorus alloy can be deposited galvanically or electrolytically on the surface
Implementation Method 2
The layer with the nickel-phosphorus alloy can be deposited galvanically or electrolytically on the surface
Implementation Method 3
a further layer of the coating is applied directly to at least part of this layer by means of gas phase deposition
Data Source
Figure 1
AI summary
The invention relates to a method for manufacturing a component (1) for a water fitting, in which a surface (2) of a base body (3) for the component (1) is at least partially coated with a coating (4) having a plurality of layers (5, 6, 7, 8), wherein at least one layer (7) of the coating is formed with a nickel-phosphorus alloy and wherein a mass fraction of the phosphorus in the nickel-phosphorus alloy is at least 8%, characterized in that a further layer (8) of the coating (4) is applied directly onto at least a part of this layer (7) by means of gas phase deposition.