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Spray coating processing SPRAY PROCESSING
Corona roller insulating coating
It is indeed feasible and effective to replace rubber and resin linings with a ceramic coating applied to metal roller bodies via thermal spray coating technology. Industrialized countries such as the United States and Japan have developed ceramic coatings for corona rollers and have achieved successful applications on these rollers.
Product Description
Sprayed Ceramic Coating Corona Roll | Corona Roll Insulating Coating | Corona Roll Ceramic Spraying Processing
Corona treatment equipment for polymer films used in packaging, printing, power, capacitors, and other fields.
Polymer films such as vinyl nitride, polyethylene, and polypropylene are lightweight, exhibit excellent mechanical properties, boast superior chemical resistance and insulation performance, and are widely used in fields including packaging, printing, power engineering, and capacitors. However, these polymers lack polar functional groups, making them chemically stable and difficult to bond with other hydrophilic groups. Therefore, prior to use, they generally undergo a preliminary corona treatment to introduce polar functional groups onto their nonpolar surfaces, thereby improving their surface tension, enhancing their vapor-depositability and printability, and facilitating direct adhesion between homogeneous or heterogeneous polymer films. During corona discharge treatment, the polymer film is passed over a dielectric corona roller equipped with a high-voltage electrode operating at several thousand to tens of thousands of volts. Consequently, the corona roller must possess outstanding insulating properties. Moreover, since corona discharge generates gases such as ozone, the roller must also demonstrate excellent chemical stability. In the past, corona rollers were typically made by embedding rubber and polymer resins—such as silicone rubber, butyl rubber, and epoxy resin—onto a metal substrate to achieve the necessary insulation. However, under corona treatment conditions, these embedded materials rapidly age and degrade, significantly shortening the roller's service life.
Ceramic materials exhibit excellent insulation properties and chemical stability; however, they are brittle, and it is extremely challenging to fabricate large-sized components using these materials. Consequently, it has been difficult to produce corona rollers made entirely of ceramic. Nevertheless, by employing thermal spray coating technology, it is entirely feasible—and indeed an effective solution—to apply a ceramic coating onto a metal roller body as a substitute for rubber or resin linings. Industrialized countries such as the United States and Japan have developed ceramic coatings for corona rollers and have achieved successful applications in this area.
Technical Solution:
★ A ceramic coating is prepared on the metal roller body using high-energy plasma spraying technology.
★ The composite structural coating is designed to prevent cracking in the Al2O3 coating and enhance its insulating properties.
★ The coating is sealed with a specialized material to prevent the presence of pores in the coating.
Process flow:
Backing roll (provided by the user; both new and used are acceptable) → Dimension inspection → Rough grinding of outer diameter → Dynamic balancing → Surface cleaning and activation → Ceramic coating application → Fine grinding and polishing → Post-coating treatment → Insulation performance testing.
Coating performance:
★ Coating adhesion strength: greater than 65 MPa;
★Microhardness: approximately HV0.3780:
★ Coating thickness (commonly used): 0.5–1.8 mm;
★Surface roughness (commonly used): Ra 0.20 μm
★ Insulation performance (commonly used): The coating remains non-puncturable under alternating voltages of 10–20 kV and frequencies of 10–30 kHz.
★ Insulation withstand voltage of over 20,000 volts and resistant to high-temperature oxidation.
★ The ceramic coating is wear-resistant and corrosion-resistant, with a service life dozens of times longer than that of silicone.
★ Case studies of well-known corona treatment machine companies.
Prev: Properties and Application Ranges of Four Common Ceramic Spraying Materials
Next: We specialize in thermal spray coating services for various industries.
Online Quotation
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Spraying equipment SPRAY EQUIPMENT
Corona roller insulating coating
It is indeed feasible and effective to replace rubber and resin linings with a ceramic coating applied to metal roller bodies via thermal spray coating technology. Industrialized countries such as the United States and Japan have developed ceramic coatings for corona rollers and have achieved successful applications on these rollers.
Product Description
Sprayed Ceramic Coating Corona Roll | Corona Roll Insulating Coating | Corona Roll Ceramic Spraying Processing
Corona treatment equipment for polymer films used in packaging, printing, power, capacitors, and other fields.
Polymer films such as vinyl nitride, polyethylene, and polypropylene are lightweight, exhibit excellent mechanical properties, boast superior chemical resistance and insulation performance, and are widely used in fields including packaging, printing, power engineering, and capacitors. However, these polymers lack polar functional groups, making them chemically stable and difficult to bond with other hydrophilic groups. Therefore, prior to use, they generally undergo a preliminary corona treatment to introduce polar functional groups onto their nonpolar surfaces, thereby improving their surface tension, enhancing their vapor-depositability and printability, and facilitating direct adhesion between homogeneous or heterogeneous polymer films. During corona discharge treatment, the polymer film is passed over a dielectric corona roller equipped with a high-voltage electrode operating at several thousand to tens of thousands of volts. Consequently, the corona roller must possess outstanding insulating properties. Moreover, since corona discharge generates gases such as ozone, the roller must also demonstrate excellent chemical stability. In the past, corona rollers were typically made by embedding rubber and polymer resins—such as silicone rubber, butyl rubber, and epoxy resin—onto a metal substrate to achieve the necessary insulation. However, under corona treatment conditions, these embedded materials rapidly age and degrade, significantly shortening the roller's service life.
Ceramic materials exhibit excellent insulation properties and chemical stability; however, they are brittle, and it is extremely challenging to fabricate large-sized components using these materials. Consequently, it has been difficult to produce corona rollers made entirely of ceramic. Nevertheless, by employing thermal spray coating technology, it is entirely feasible—and indeed an effective solution—to apply a ceramic coating onto a metal roller body as a substitute for rubber or resin linings. Industrialized countries such as the United States and Japan have developed ceramic coatings for corona rollers and have achieved successful applications in this area.
Technical Solution:
★ A ceramic coating is prepared on the metal roller body using high-energy plasma spraying technology.
★ The composite structural coating is designed to prevent cracking in the Al2O3 coating and enhance its insulating properties.
★ The coating is sealed with a specialized material to prevent the presence of pores in the coating.
Process flow:
Backing roll (provided by the user; both new and used are acceptable) → Dimension inspection → Rough grinding of outer diameter → Dynamic balancing → Surface cleaning and activation → Ceramic coating application → Fine grinding and polishing → Post-coating treatment → Insulation performance testing.
Coating performance:
★ Coating adhesion strength: greater than 65 MPa;
★Microhardness: approximately HV0.3780:
★ Coating thickness (commonly used): 0.5–1.8 mm;
★Surface roughness (commonly used): Ra 0.20 μm
★ Insulation performance (commonly used): The coating remains non-puncturable under alternating voltages of 10–20 kV and frequencies of 10–30 kHz.
★ Insulation withstand voltage of over 20,000 volts and resistant to high-temperature oxidation.
★ The ceramic coating is wear-resistant and corrosion-resistant, with a service life dozens of times longer than that of silicone.
★ Case studies of well-known corona treatment machine companies.
Prev: Properties and Application Ranges of Four Common Ceramic Spraying Materials
Next: We specialize in thermal spray coating services for various industries.
Online Quotation
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