Cold Gas Dynamic Spraying Mask for Conductor Precision
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Solution Overview
Problem
In cold gas dynamic spraying, the production of printed conductors is hindered by unfavorable flow conditions caused by the ratio of mask opening width to thickness, leading to backflow and triangular cross-section deposition, which results in insufficient material adherence to mask walls and inaccurate geometry of the coated surface.
Innovation Solution
A method where a mask is placed on the carrier component, and material is deposited in the mask opening until it is completely filled, with subsequent removal of excess material to create a flat surface, allowing additional masks to be layered and filled until the desired thickness is achieved, ensuring accurate geometry and adherence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mask with small opening width is used to produce printed conductors, then the conductor pattern precision is improved, but the deposition becomes difficult due to unfavorable flow conditions and backflow
Solution Approach 1:
The mask is pre-positioned on the substrate before the spraying process begins. The mask openings are precisely aligned with the desired conductor patterns, establishing the geometric framework before material deposition occurs. This preliminary positioning ensures that the supersonic particle jet deposits material only within the defined opening boundaries, achieving precise conductor patterns while preventing backflow into unwanted areas.
Solution Approach 2:
The mask serves as an intermediary element between the supersonic particle jet and the substrate. It mediates the flow conditions by providing a physical barrier with controlled openings, transforming the chaotic supersonic flow into directed deposition streams. The mask walls guide the particle flow, preventing backflow and ensuring material adheres only to the intended substrate areas, thus solving both precision and deposition difficulty issues.
2Ease of manufacture
If the mask is placed at a certain distance from the carrier component, then the flow conditions are improved, but the flanks of the sprayed surfaces extend beyond the mask opening dimensions
Solution Approach 1:
The mask is pre-positioned in direct contact with the substrate surface before spraying begins. This preliminary placement establishes the mask openings as the exact boundaries for material deposition. By eliminating the distance gap, the mask walls remain in intimate proximity to the substrate throughout the spraying process, ensuring that the supersonic particle jet deposits material with rectangular cross-sections that precisely match the mask opening dimensions, preventing flank extension.
Solution Approach 2:
The mask design employs asymmetric thickness distribution relative to the opening dimensions. The mask thickness is specifically engineered to be sufficient to prevent backflow and guide the particle jet, yet thin enough to allow adequate material penetration. This asymmetric relationship between mask thickness and opening width creates optimal flow conditions while maintaining precise rectangular cross-section geometry in the deposited conductors.
3Stability of the object's composition
If the mask opening width to thickness ratio is small, then the mask structure is stable, but backflow occurs leading to triangular cross section deposition
Solution Approach 1:
The mask geometry parameters, specifically the opening width, opening height, and thickness ratios, are precisely controlled within optimized ranges. The opening width and height are dimensioned to provide sufficient structural stability, while the thickness is maintained at a specific proportion that prevents backflow. These parameter changes transform the mask from a structurally stable but flow-unfriendly design to one that simultaneously achieves both stability and precise rectangular deposition by optimizing the balance between structural integrity and flow guidance.
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 approach enables the production of coatings with high geometric accuracy and rectangular cross-sections, preventing backflow and ensuring the material adheres only to the intended surface, improving the quality and precision of the coating process.
Implementation Method 1
a gas heating device for heating a gas
Implementation Method 2
particles for the coating are accelerated to supersonic speed by means of a convergent-divergent nozzle
Implementation Method 3
on account of their impressed kinetic energy
Implementation Method 4
the kinetic energy of the particles leads to a plastic deformation, wherein the coating particles upon impact are fused only on their surface
Implementation Method 5
the coating particles upon impact are fused only on their surface
Data Source
AI summary
The present disclosure relates to coating a carrier component by means of cold gas dynamic spraying. For example, a method for coating a carrier component may include: laying a mask with an opening on the component; depositing a material through the opening to completely fill up the mask opening; removing any material located above the upper side to form a flat surface even with the upper side of the mask; laying a second mask on the first mask; depositing the material again; removing any deposited material located above the upper side of the second mask to form a flat surface even with the upper side of the second mask; repeating layers of additional masks and material deposition until the deposited material reaches a required thickness on the carrier component; and after completion of the coating to the required thickness, removing the masks.