Aluminium Oxide Hydroxide Coating for Uniform Complex Surfaces
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Solution Overview
Problem
Existing methods for producing aluminium oxide hydroxide-coated substrates, such as atomic layer deposition and wet-chemistry processes, are expensive, lack control over coating uniformity, and are inefficient for irregular surfaces, while wet-chemistry methods produce waste and require additional processing steps.
Innovation Solution
A method involving the simultaneous feeding of aluminium nitrate and basic solution streams into a liquid at elevated temperature and controlled pH to form an aluminium oxide hydroxide slurry, followed by substrate contact and separation, allowing for controlled hydration and thickness of the coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If atomic layer deposition is used to coat the substrate, then the coating uniformity and thickness control are improved, but the manufacturing cost and device complexity increase significantly
Solution Approach 1:
The patent replaces expensive, complex atomic layer deposition equipment with simple, inexpensive wet-chemistry coating apparatus. The coating process uses basic chemical solutions and standard laboratory equipment rather than specialised deposition chambers, dramatically reducing device complexity while maintaining coating quality through controlled chemical reactions.
Solution Approach 2:
The patent controls coating thickness and uniformity by adjusting chemical parameters such as solution concentration, pH, temperature, and reaction time rather than relying on complex physical deposition controls. This allows precise thickness control through simple parameter adjustment of the chemical bathing process.
2Manufacturing precision
If atomic layer deposition is used to coat irregular surfaces, then conformal coating is achieved, but the effectiveness decreases on irregular-shaped form factors
Solution Approach 1:
The patent uses liquid chemical solutions that naturally flow and penetrate irregular surfaces through capillary action and gravity, providing conformal coating on complex geometries. The liquid bathing process adapts to any surface shape without requiring specialised deposition geometry, enhancing versatility for irregular-shaped substrates.
3Ease of manufacture
If wet-chemistry processes are used to coat the substrate, then the manufacturing cost and process simplicity are improved, but the coating quality control and uniformity deteriorate
Solution Approach 1:
The patent implements pH monitoring and control during the wet-chemistry coating process to ensure consistent coating quality. By maintaining specific pH ranges and adjusting chemical concentrations based on process conditions, the method achieves uniform coating deposition while keeping the process simple and cost-effective.
Solution Approach 2:
The patent achieves controlled coating quality by systematically adjusting chemical parameters including solution concentration, pH, temperature, and exposure time. These parameter optimizations ensure complete and uniform coating coverage while maintaining process simplicity and low cost through standard chemical techniques.
4Ease of manufacture
If wet-chemistry methods are used for coating, then the process simplicity is improved, but waste liquid production and additional processing steps increase
Solution Approach 1:
The patent optimizes the wet-chemistry process to minimize waste liquid generation by controlling reaction efficiency and coating completion. The method achieves complete coating deposition with minimal excess solution, reducing the volume of waste liquid requiring disposal while maintaining process simplicity.
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
This method achieves high-purity, uniform aluminium oxide hydroxide coatings on complex surfaces, reducing thermal runaway and corrosion risks in battery cells, and is more cost-effective and reliable than existing processes.
Implementation Method 1
forming an aluminium oxide hydroxide slurry by simultaneously feeding streams of an aluminium nitrate solution and a basic solution, such as an ammonia solution, into a liquid over a reaction period
Data Source
AI summary
A method for producing a coated substrate is described that includes forming an aluminium oxide hydroxide slurry by simultaneously feeding streams of an aluminium nitrate solution and a basic solution, such as an ammonia solution, into a liquid over a reaction period, while maintaining an elevated temperature and a controlled pH; allowing a substrate to contact the slurry to thereby form an aluminium oxide hydroxide coating on the substrate; and separating the coated substrate from the liquid.