PFI-RP: Low-Friction Durable Coatings for Improving Energy Efficiency in Conveyor Systems

该创新-研究伙伴关系（PFI-RP）项目的广泛影响/商业潜力将显著降低输送系统的能耗和设备故障。该项目提出了一种新的涂层技术，比目前使用的石油基润滑油更具环境可持续性。这项技术将使其他领域的应用成为可能，并在多个行业产生巨大的节约。该项目将进一步为研究生和本科生，特别是来自代表性不足群体的学生，提供创新和创业方面的广泛教育和领导培训。他们将获得领先的高科技创业公司所需的知识和技能。该项目提出了一种将石墨涂层紧密粘合在基体上的方法，这在以前是不可能的。该项目将解决带式输送机应用涂层技术发展中的几个技术挑战。具体目标是1)开发和优化输送机材料的快速涂层沉积工艺，2)开发全尺寸输送机材料的可扩展涂层工艺，3)构建原型带式输送机以评估涂层性能，以及4)证明所开发的涂层用于带式输送机应用的可行性。这项研究将有助于从根本上了解涂层沉积参数和涂层成分如何影响涂层的形貌、厚度、与基体的附着力、凝聚力、摩擦和耐久性。预期的技术成果是生产干润滑传送带和滑块床材料，在原型输送机中，与未涂覆的材料相比，这些材料的摩擦和耐用性至少提高了50%。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

The broader impact/commercial potential of this Partnerships for Innovation – Research Partnerships (PFI-RP) project will significantly reduce the energy consumption and equipment failure in conveyor systems. The proposed project advances a new coating technology that is more environmentally sustainable than currently used petroleum-based oil lubricants. This technology will enable applications in other fields and produce tremendous savings in multiple industries. The project will further provide extensive education and leadership training in innovation and entrepreneurship to graduate and undergraduate students, particularly those from underrepresented groups. They will gain the required knowledge and skills for leading high-tech startup companies.The proposed project advances a method to bond graphite coatings tightly to a substrate, which has not been possible previously. This project will address several technical challenges in the development of the coating technology for belt conveyor applications. The specific objectives are to 1) develop and optimize fast coating deposition processes on conveyor materials, 2) develop scalable coating processes for full-size conveyor materials, 3) build a prototype belt conveyor for evaluating the coating performance, and 4) demonstrate the feasibility of the developed coatings for belt conveyor applications. This research will contribute to the fundamental understanding of how coating deposition parameters and coating composition affect coating morphology, thickness, adhesion to the substrate, cohesion, friction, and durability. The expected technical outcome is the production of dry-lubricated conveyor belts and slider bed materials that show a friction and durability improvement of at least 50% over uncoated materials in a prototype conveyor.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.