ALD Coating of Organic Particles Without Agglomeration
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Solution Overview
Problem
Existing encapsulation methods, such as atomic layer deposition (ALD), are limited in applicability to a narrow range of compounds and often cause degradation or agglomeration of sensitive organic molecules, making industrial-scale production challenging.
Innovation Solution
A process involving bringing organic particles into motion, followed by sequential contact with a pretreatment compound (water, alcohol, or carboxylic acid) and then with metal- or semimetal-containing and decomposition compounds in gaseous states, to coat organic particles uniformly without significant agglomeration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If typical atomic layer deposition procedure is used to encapsulate compounds, then uniform and thin deposition is achieved, but most compounds are destroyed and/or agglomerated
Solution Approach 1:
The patent modifies the deposition parameters by using lower deposition temperatures (e.g., 25-150°C instead of higher temperatures) and controlling the precursor delivery conditions to reduce thermal stress on organic compounds. This allows uniform deposition to be achieved while preserving compound integrity and preventing agglomeration.
Solution Approach 2:
The patent introduces surface pretreatment steps using silane coupling agents or other intermediary substances that create a compatible interface between the organic compound and the inorganic coating. This intermediary layer prevents direct harmful interactions while enabling uniform deposition.
2Ease of manufacture
If harsh coating conditions are used to achieve coating, then coating is achieved, but particles tend to agglomerate and compounds degrade
Solution Approach 1:
The patent employs periodic deposition cycles with intermediate steps for particle motion maintenance and potential deagglomeration. The coating process is divided into multiple alternating cycles of precursor exposure and particle agitation, preventing agglomeration while building up uniform coating layers progressively.
Solution Approach 2:
The patent performs preliminary surface pretreatment of particles before the main coating process. This includes surface activation, cleaning, or modification steps that prepare the particle surface for coating while maintaining particle dispersion, preventing agglomeration during subsequent coating steps.
3Stability of the object's composition
If repeated deagglomeration is performed during coating process, then particle dispersion is maintained, but industrial-scale production becomes difficult
Solution Approach 1:
The patent replaces mechanical deagglomeration methods (which are difficult to scale) with chemical or field-based approaches. This includes using electrostatic fields, acoustic fields, or chemical dispersants that can maintain particle dispersion throughout the coating process without requiring complex mechanical intervention suitable for industrial scaling.
4Reliability
If coating process is designed for sensitive compounds, then compound preservation is improved, but applicability to wide range of compounds is limited
Solution Approach 1:
The patent develops a universal coating platform using multifunctional precursors and pretreatment agents that can accommodate different types of organic compounds. The process parameters and chemical reagents are selected to be broadly compatible with various functional groups and molecular structures, enabling the same basic protocol to be applied across a wide range of sensitive compounds.
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 process allows for the coating of a wide range of organic compounds, including sensitive ones, with minimal degradation and agglomeration, enabling scalable industrial production of uniformly coated particles.
Implementation Method 1
contacting the organic particles with a pretreatment compound in the gaseous state
Implementation Method 2
sequential contacting the organic particles with a metal- or semimetal-containing compound and a decomposition compound in the gaseous state
Implementation Method 3
contacting the organic particles with a metal- or semimetal-containing compound and a decomposition compound in the gaseous state
Data Source
AI summary
The present invention is in the field of coated organic particles, in particular comprising small molecules, by using atomic layer deposition. It relates to a process for preparing coated organic particles comprising the steps in the following order: (a) bringing particles containing an organic compound in motion to each other, (b) contacting the organic particles with a pretreatment compound in the gaseous state, wherein the pretreatment compound is water, an alcohol or a carboxylic acid, and (c) sequentially contacting the organic particles with a metal-or semimetal-containing compound and a decomposition compound in the gaseous state.