Coated Corona Ionization Source Wire for Reliable Attachment
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Solution Overview
Problem
Fabricating a reliable corona ionization source for ion mobility spectrometry and mass spectrometry is challenging due to the fragility and difficulty in attaching a fine wire to posts while maintaining a reliable electrical connection, as previous methods like crimping, welding, and soldering are unreliable.
Innovation Solution
A corona ionization source assembly is developed with a fine wire core and a wire coating of a second material, where the wire coating surrounds the core and has a greater diameter, and is coupled to a post for mechanical and electrical support, using a process involving forming the wire core, coating, masking, etching, and removing the mask layer to create a stable and efficient ionization source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a fine wire is used for corona ionization source, then the high voltage requirements are reduced and ionization efficiency is improved, but the wire becomes fragile and difficult to attach to posts reliably
Solution Approach 1:
The wire structure is segmented into a fine wire core (for ionization function) and a separate coating layer (for mechanical strength). This allows the fine core to maintain low voltage requirements while the coating provides structural integrity and reliable attachment capability.
Solution Approach 2:
The corona wire is constructed as a composite structure with a fine wire core surrounded by a coating of different material properties. The core material (e.g., platinum, tungsten) provides ionization efficiency at low voltage, while the coating material provides mechanical strength and facilitates reliable attachment to posts without compromising the core's electrical properties.
2Productivity
If a fine wire is used for corona ionization source, then the ionization efficiency is improved, but the handling and attachment difficulty increases
Solution Approach 1:
The wire is segmented into functional core and structural coating components, allowing each to be optimized independently. The fine core maximizes ionization efficiency while the separate coating layer simplifies handling and attachment processes.
Solution Approach 2:
The coating acts as an intermediary between the fragile fine wire core and the attachment post. It provides a mechanically robust interface for attachment while leaving the fine core exposed for ionization, thereby facilitating ease of manufacture without compromising ionization efficiency.
3Strength
If traditional attachment methods (crimping, welding, soldering) are used on fine wires, then mechanical support is provided, but the attachment reliability is poor
Solution Approach 1:
The composite wire structure allows the coating to serve as the primary attachment interface, which can be made of materials optimized for mechanical strength and attachment reliability. The fine core remains intact and functional, avoiding the damage and reliability issues associated with applying crimping, welding, or soldering directly to fine wires.
Solution Approach 2:
The coating serves as an intermediary layer between the fine wire core and the attachment post, bearing the mechanical attachment loads while protecting the fragile core. This intermediary structure enables reliable attachment through conventional methods without compromising the core's integrity or the overall attachment reliability.
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 solution provides a robust and efficient corona ionization source that overcomes the fragility and attachment issues of fine wires, enabling reliable operation with lower high voltage requirements and improved handling, enhancing the performance of ion mobility and mass spectrometry systems.
Implementation Method 1
a wire coating including a second material, where the wire coating surrounds a portion of the wire core
Implementation Method 2
A corona ionization source assembly and methods for fabricating the corona ionization source assembly are described
Implementation Method 3
a fine wire including a wire core including a first material, and a wire coating including a second material
Data Source
Figure 1A~1C
Figure 1D
Figure 2
AI summary
A corona ionization source assembly and fabrication methods are described that include a fine wire including a wire core including a first material, and a wire coating including a second material, where the wire coating surrounds a portion of the wire core, and the diameter of the wire coating is greater than the diameter of the wire core. Additionally, the fine wire may be coupled to a mounting post. In an implementation, a process for fabricating the corona ionization source assembly that employs the techniques of the present disclosure includes forming a wire core, forming a wire coating that surrounds the wire core, forming a mask layer on at least a portion of the wire coating, etching the wire coating, and removing the mask layer from the wire coating.