CN116329019A - 一种具备复合保护层的涂布头及其加工工艺 - Google Patents

一种具备复合保护层的涂布头及其加工工艺 Download PDF

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CN116329019A
CN116329019A CN202310253498.1A CN202310253498A CN116329019A CN 116329019 A CN116329019 A CN 116329019A CN 202310253498 A CN202310253498 A CN 202310253498A CN 116329019 A CN116329019 A CN 116329019A
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CN116329019B (zh
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庞学谦
彭建林
张中春
唐岳静
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Shenzhen Manst Technology Co Ltd
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Abstract

本发明提供一种具备复合保护层的涂布头及其制备工艺，所述涂布头包括涂布头本体、热喷涂层和PVD镀膜层，涂布头本体具有工作面和刃口，刃口朝向工作面的一侧开设有凹槽，热喷涂层设置在凹槽内，且热喷涂层的厚度与凹槽深度一致，使热喷涂层与工作面平齐，热喷涂层涂布在刃口靠近工作面的一侧，PVD镀膜层包覆在整个涂布头本体上，使热喷涂层位于PVD镀膜层的内侧。本发明所提供的涂布头，利用设置在PVD镀膜层内侧的热喷涂层，可对涂布头的刃口多重保护，有效防止涂布头的刃口被磨损和腐蚀，提高涂布头的使用寿命。

Description

一种具备复合保护层的涂布头及其加工工艺
技术领域
本发明涉及涂布头表面强化镀层的技术领域，具体涉及一种具备复合保护层的涂布头及其加工工艺。
背景技术
在锂电池生产过程中，浆料从涂布头的进料口进入模头内部型腔中，并形成稳定压力，再经过涂布头的刃口和模头的狭缝出口喷出，涂布在箔材上，涂布头的刃口性能则影响着浆料的涂布效果。
目前，涂布头大都采用不锈钢制成，其硬度一般在38－42HRC，并在涂布头上设有PVD镀层，以加强涂布头的表面强度，提高涂布头的耐磨性能。但由于PVD镀膜在局部会存在细小的缺陷，涂布过程中，浆料容易透过细小缺陷直接与涂布头接触，磨损涂布头，涂布头的耐磨性能较差，使用寿命短。
发明内容
因此，为了解决现有技术中采用PVD镀层的涂布头的耐磨性能差、使用寿命短的缺陷，本发明提供了一种具有复合保护层的涂布头及其制备工艺。
第一方面，本发明提供的具有复合保护层的涂布头，采用如下的技术方案：
一种具有复合保护层的涂布头，包括：
涂布头本体，其上具有刃口和工作面，所述刃口朝向所述工作面的一侧设有凹槽；
热喷涂层，涂布在所述凹槽内，其表面与所述工作面平齐；
PVD镀膜层，涂布在所述涂布头本体上，将所述热喷涂层包覆在内侧。
可选地，所述凹槽与所述工作面的衔接处设有过渡圆角。
可选地，所述过渡圆角的角度为10－80°。
可选地，所述凹槽的宽度为10－20mm、深度为0.1－1mm。
可选地，所述PVD镀膜层的厚度为2－8μm。
可选地，所述热喷涂层为WC－10Co－4Cr，所述PVD镀膜层为CrN。
另一方面，本发明提供的对上述任意一种实施方式中具有复合保护层的涂布头的制备工艺，采用如下的技术方案：
一种涂布头的制备工艺，至少包括如下步骤；
在涂布头本体的刃口处加工所述凹槽；
打磨所述凹槽的内壁，并对所述涂布头本体进行清洗后吹干；
向凹槽内喷涂所述热喷涂层；
对所述热喷涂层表面打磨抛光处理，并对打磨后的所述涂布头本体再次清洗吹干；
对涂布头本体进行PVD镀膜，形成所述PVD镀膜层。
可选地，所述制备工艺还包括如下步骤：
对所述凹槽内壁打磨、清洗及吹干后，对所述凹槽的内壁进行喷砂粗化处理。
可选地，所述制备工艺还包括如下步骤：
对所述凹槽内壁进行喷砂粗化处理前，使用耐热的玻璃布将涂布头本体的非热喷涂部位包裹遮蔽。
可选地，所述制备工艺还包括如下步骤：将热喷涂后的涂布头本体放入保温设备中缓慢降温。
本发明技术方案，具有如下优点：
1.本发明提供的具有复合保护层的涂布头，通过在刃口出设置热喷涂层，配合外侧的PVD镀膜层，对涂布头的刃口进行双重保护，在涂布过程中透过PVD镀膜层缺陷的浆料会被热喷涂层阻挡，而无法与涂布头本体直接接触，进而避免了涂布头本体的腐蚀磨损，提高了涂布头的使用寿命。
2.本发明提供的具有复合保护层的涂布头，通过在刃口部位开设凹槽的方式，提供了热喷涂层的设置空间，既保证了刃口处具有足够厚度的热喷涂层，又使热喷涂层表面与工作面平齐，利于后续PVD镀膜层的成型。并且，凹槽与工作面衔接处的过渡圆角，也使热喷涂层与工作面的接缝较小，浆料也不易从缝隙处渗透。
3.本发明提供的涂布头的制备工艺，通过先在涂布头本体处开设凹槽，再向凹槽内进行热喷涂，从而在刃口处形成足够厚度的热喷涂层，并且在进行PVD镀膜前对热喷涂层表面进行打磨抛光处理，确保热喷涂层与工作面的平起程度，减小热喷涂层与工作面之间的缝隙，利于后续的PVD镀膜层成型。
4.本发明提供的涂布头的制备工艺，在向凹槽内设置热喷涂层之前，通过向凹槽内壁进行喷砂粗化处理，可增大凹槽内壁的粗糙度，提高热喷涂层在凹槽内的附着强度和紧密程度，并且在粗化处理时可使用耐热的玻璃布将涂布头本体的其他部位包裹，避免喷砂过程影响其他部位。
5.本发明提供的涂布头的制备工艺，在热喷涂层成型后，通过将涂布头本体置于保温设备中缓慢降温，有利于热喷涂层的成型稳定和成型质量。
附图说明
为了更清楚地说明本发明具体实施方式或现有技术中的技术方案，下面将对具体实施方式或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图是本发明的一些实施方式，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为涂布头本体的正视图；
图2为涂布头本体的侧视图；
图3为图2中A部分的放大图；
图4为设置在涂布头本体上的热喷涂层和PVD层的结构示意图；
附图标记说明：1、涂布头本体；2、刃口；3、工作面；4、凹槽；5、热喷涂层；6、PVD镀膜层。
具体实施方式
下面将结合附图对本发明的技术方案进行清楚、完整地描述，显然，所描述的实施例是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
在本发明的描述中，需要说明的是，术语“中心”、“上”、“下”、“左”、“右”、“竖直”、“水平”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本发明和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本发明的限制。此外，术语“第一”、“第二”、“第三”仅用于描述目的，而不能理解为指示或暗示相对重要性。
在本发明的描述中，需要说明的是，除非另有明确的规定和限定，术语“安装”、“相连”、“连接”应做广义理解，例如，可以是固定连接，也可以是可拆卸连接，或一体地连接；可以是机械连接，也可以是电连接；可以是直接相连，也可以通过中间媒介间接相连，可以是两个元件内部的连通。对于本领域的普通技术人员而言，可以根据具体情况理解上述术语在本发明中的具体含义。
此外，下面所描述的本发明不同实施方式中所涉及的技术特征只要彼此之间未构成冲突就可以相互结合。
本实施例提供一种具有复合保护层的涂布头，结合图1至图4所示，涂布头包括涂布头本体1、热喷涂层5和PVD镀膜层6，其中，涂布头本体1具有工作面3和刃口2，刃口2朝向工作面3的一侧开设有凹槽4，热喷涂层5设置在凹槽4内，且热喷涂层5的厚度与凹槽4深度一致，使热喷涂层5与工作面3平齐，热喷涂层5涂布在刃口2靠近工作面3的一侧，PVD镀膜层6包覆在整个涂布头本体1上，使热喷涂层5位于PVD镀膜层6的内侧。
其中，热喷涂层5是通过用高速气流将加热熔化的涂层材料雾化为极细的颗粒，并以很高的速度喷射在涂布头本体1表面所形成的涂层，其可提高涂布头本体1刃口2部位的耐磨损、耐腐蚀、抗氧化以及耐热等性能。通过热喷涂层5，能够形成对刃口2部位的二次保护，可避免透过PVD镀膜上细小缺陷浆料直接与刃口2部位接触，以此提高涂布头的耐磨性能，延长使用寿命。
热喷涂层5可选用WC－Co、WC－Ni、WC－Co－Cr、Cr2O3、Cr3C2、TiC、Al2O3等组合涂层以及其他组合喷涂涂层，热喷涂层5可采用超音速火焰喷涂、超音速等离子喷涂、爆炸喷涂以及热喷涂设备等方式进行喷涂。
凹槽4的宽度可根据刃口2的大小设置为10－20mm，凹槽4的深度可设置为0.1－1mm，深度最优选择0.3－0.7mm，既能保证热喷涂层5具有足够的厚度，又能保证凹槽4的开设不影响刃口2的结构强度。
进一步地，在一些实施例中，结合图3和图4所示，凹槽4与工作面3的衔接处可设置过渡圆角，过渡圆角的大小可根据凹槽4的深度选择10－80°，最优选择25－60°。利用过渡圆角使热喷涂层5与工作面3的衔接处缝隙更小，渗透过PVD镀膜层6的浆料不易透过缝隙与涂布头本体1接触。
另外，上述中的PVD镀膜层6可采用磁控、电子枪或多弧等镀膜设备进行镀膜，PVD镀膜层6可选用CrN、Cr2O3、CrWN、CrSiN、CrAlN以及其他硬质涂层，PVD镀膜层6的厚度可根据涂布头本体1的大小选择2－8μm，硬度为1800－4000HV。
基于上述的涂布头，本发明实施例还提供一种涂布头的制备工艺，结合图1至图4所示，制备工艺至少包括如下步骤：
在涂布头本体1的刃口2处加工凹槽4。具体地，可采用CNC机床在刃口2处加工槽，凹槽4的宽度河深度根据刃口2部位的大小进行适应性选择。
打磨凹槽4的内壁，并对涂布头本体1进行清洗后吹干。具体地，可利用磨床对凹槽4内壁进行打磨处理，清洗时可采用丙酮或其他清洗剂，通过清洗和吹干后去除涂布头本体1表面的油渍，利于后续的热喷涂层5成型。
向凹槽4内喷涂热喷涂层5。具体地，热喷涂层5可选用WC－Co、WC－Ni、WC－Co－Cr、Cr2O3、Cr3C2、TiC、Al2O3等组合涂层以及其他组合喷涂涂层，且可采用超音速火焰喷涂、超音速等离子喷涂、爆炸喷涂以及热喷涂设备等方式进行喷涂。
对热喷涂层5表面打磨抛光处理，并对打磨后的涂布头本体1再次清洗吹干。具体地，同样可采用磨床进行打磨抛光处理，且可利用丙酮或酒精对涂布头进行超声清洗并吹干后，以去除涂布头表面在热喷过程中的杂质及油渍，利于后续PVD镀膜层6的成型。
对涂布头本体1进行PVD镀膜，形成PVD镀膜层6。具体地，PVD镀膜层6可采用磁控、电子枪或多弧等镀膜设备进行镀膜，PVD镀膜层6可选用CrN、Cr2O3、CrWN、CrSiN、CrAlN以及其他硬质涂层，PVD镀膜层6的厚度可根据涂布头本体1的大小选择2－8μm。
在一些实施例中，涂布头本体1的制备工艺还可包括步骤：对凹槽4内壁打磨、清洗及吹干后，对凹槽4的内壁进行喷砂粗化处理。具体地，可利用压力0.3MP、250#玉刚砂进行粗化处理，增大凹槽4内壁的粗糙程度，利于热喷涂层5的附着。
进一步地，在对凹槽4内壁进行喷砂粗化处理前，可使用耐热的玻璃布将涂布头本体1的非热喷涂部位包裹遮蔽，避免喷砂过程影响到涂布头本体1的其他部位。
另外，在一些实施例中，涂布头本体1的制备工艺还可包括步骤：将热喷涂后的涂布头本体1放入保温设备中缓慢降温，以利于热喷涂层5的成型稳定和成型质量。
以下结合实施例1－实施例3，对采用上述的制备工艺得到的涂布头进行耐冲刷强度测试和分析。
实施例1
在本实施例中，凹槽4的宽度为15mm、深度为0.5mm。
热喷涂层5采用煤油－氧超音速火焰喷涂进行喷涂，喷涂材料选用WC－10Co－4Cr。在喷涂前，先通入氧气与煤油清理喷枪内杂质，用喷枪对涂布头本体1预热，预热温度为350℃。随后通入WC－10Co－4Cr粉末，粉末粒度为10－50μm，在喷涂过程中：氧气流量60m3/h、氧气压力0.4Mpa、煤油流量0.4L/min、送粉量1g/s、喷距380mm、移动速度1.5m/min、厚度0.55mm、硬度1100HV。
PVD镀膜层6通过多弧镀膜工艺，PVD镀膜层6选用CrN材料。具体地，先在偏压300V、弧电流为80A的条件下，通入氩气，达到一定分压后关掉氩气。采用Cr金属靶，在喷涂的涂布头本体1表面采用PVD工艺沉积Cr金属以形成厚度为1μm的结合层，随后再通入氮气，在偏压80－100V的条件下，调整Cr靶弧电流80A到100A，采用PVD工艺在结合层的表面沉CrN合金形成厚度为4μm的PVD镀膜层6，PVD镀膜层6的表面硬度为2100HV。
实施例2
本实施例与实施例1的不同之处在于，在本实施例中，热喷涂层5采用NiCr－Cr2C3材料，在喷涂过程中：氧气流量50m3/h、喷距应300mm、移动速度1m/min、厚度0.50mm、硬度950HV。
实施例3
本实施例与实施例1的不同之处在于，在本实施例中，PVD镀膜层6采用AlCrN合金，在PVD镀膜过程中，通入氮气后，在偏压120V的条件下，调整AlCr靶弧电流至100A－120A，采用PVD工艺在结合层的表面沉AlCrN合金形成厚度为4μm的PVD涂层，PVD的表面硬度为3000HV左右。
采用如下的测试方案测试实施例1－实施例3中的涂布头的耐磨损强度：
使用3：7比例的1250目砂与水的混合液体，模拟涂布过程中的浆料，在同种喷射压力下，令喷枪与涂布头之间的角度为30°、喷涂距离100mm、喷涂时间6h，对涂布头进行冲刷。在冲刷试验完成后，通过三维轮廓仪测试冲刷深度，基于磨损深度判断涂布头的耐磨损强度。
测试结果如下：
方案 镀膜种类 硬度 磨损深度
实施例1 热喷涂层(WC－10Co－4Cr)+PVD镀膜层(CrN) 2100HV 8.8μm
实施例2 热喷涂层(NiCr－Cr2C3)+PVD镀膜层(CrN) 2100HV 6.3μm
实施例3 热喷涂层(WC－10Co－4Cr)+PVD镀膜层(AlCrN) 3000HV 5.3μm
对比例1 仅设置PVD镀膜层(CrN) 2100HV 13.8μm
对比例2 无镀膜 420HV 32.5μm
通过上述测试可知，采用热喷涂层5与PVD镀膜层6的结合使用，涂布头在相同冲刷条件下，涂布头的磨损深度相比于单纯设置PVD镀膜层6或未设置保护层明显变小，尤其在热喷涂层5为WC－10Co－4Cr、PVD镀膜层6为CrN时效果最佳，提高了涂布头的使用寿命。
显然，上述实施例仅仅是为清楚地说明所作的举例，而并非对实施方式的限定。对于所属领域的普通技术人员来说，在上述说明的基础上还可以做出其他不同形式的变化或变动。这里无需也无法对所有的实施方式予以穷举。而由此所引申出的显而易见的变化或变动仍处于本发明创造的保护范围之中。

Claims (10)

1.一种具备复合保护层的涂布头，其特征在于，包括：
涂布头本体(1)，其上具有刃口(2)和工作面(3)，所述刃口(2)朝向所述工作面(3)的一侧设有凹槽(4)；
热喷涂层(5)，涂布在所述凹槽(4)内，其表面与所述工作面(3)平齐；
PVD镀膜层(6)，涂布在所述涂布头本体(1)上，将所述热喷涂层(5)包覆在内侧。
2.根据权利要求1所述的涂布头，其特征在于，所述凹槽(4)与所述工作面(3)的衔接处设有过渡圆角。
3.根据权利要求2所述的涂布头，其特征在于，所述过渡圆角的角度为10－80°。
4.根据权利要求1所述的涂布头，其特征在于，所述凹槽(4)的宽度为10－20mm、深度为0.1－1mm。
5.根据权利要求1所述的涂布头，其特征在于，所述PVD镀膜层(6)的厚度为2－8μm。
6.根据权利要求1－5中任一项所述的涂布头，其特征在于，所述热喷涂层(5)为WC－10Co－4Cr，所述PVD镀膜层(6)为CrN。
7.一种对权利要求1－6中任一项所述的涂布头的制备工艺，其特征在于，所述制备工艺包括如下步骤：
在涂布头本体(1)的刃口(2)处加工所述凹槽(4)；
打磨所述凹槽(4)的内壁，并对所述涂布头本体(1)进行清洗后吹干；
向凹槽(4)内喷涂所述热喷涂层(5)；
对所述热喷涂层(5)表面打磨抛光处理，并对打磨后的所述涂布头本体(1)再次清洗吹干；
对涂布头本体(1)进行PVD镀膜，形成所述PVD镀膜层(6)。
8.根据权利要求7所述的涂布头的制备工艺，其特征在于，所述制备工艺还包括如下步骤：
对所述凹槽(4)内壁打磨、清洗及吹干后，对所述凹槽(4)的内壁进行喷砂粗化处理。
9.根据权利要求8所述的涂布头的制备工艺，其特征在于，所述制备工艺还包括如下步骤：
对所述凹槽(4)内壁进行喷砂粗化处理前，使用耐热的玻璃布将涂布头本体(1)的非热喷涂部位包裹遮蔽。
10.根据权利要求7－9中任一项所述的涂布头的制备工艺，其特征在于，所述制备工艺还包括如下步骤：
将热喷涂后的涂布头本体(1)放入保温设备中缓慢降温。
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