Composite Particle Synthesis via Thermal Plasma Evaporation
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Solution Overview
Problem
Existing methods for manufacturing composite particles with copper compound-carried titanium oxides are costly, complex, and require multiple steps, including liquid phase synthesis, which limits solvent options and complicates particle use.
Innovation Solution
A method involving thermal plasma evaporation and cooling to synthesize composite particles, where a first raw material (copper, molybdenum, or silver) is evaporated and cooled to generate fine particles with sizes between 0.5 nm and 300 nm, which are then carried on the surface of a second raw material (aluminum, titanium, etc.) particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid phase method is used to manufacture copper compound-carried titanium oxides, then photocatalytic activity can be achieved, but manufacturing cost increases and process complexity increases
Solution Approach 1:
The patent replaces the liquid phase chemical synthesis method with a physical vapor deposition method using sputtering. This substitution eliminates the need for complex chemical reducing agents and solvent treatments, directly depositing copper compounds onto titanium oxide particles through physical vapor transport, thereby simplifying the manufacturing process while maintaining photocatalytic functionality
Solution Approach 2:
The patent changes the manufacturing parameters from liquid phase chemistry (requiring reducing agents, solvents, and temperature-controlled chemical reactions) to physical vapor deposition parameters (controlling sputtering power, gas flow rates, and deposition time). This parameter transformation enables direct formation of copper compound coatings without complex chemical processing steps
2Ease of manufacture
If liquid phase synthesis is used, then composite particles can be synthesized, but solvent selection is limited and additional treatment is required
Solution Approach 1:
The patent replaces liquid phase synthesis with physical vapor deposition, eliminating the solvent-based chemical process entirely. This allows for direct deposition of copper compounds onto titanium oxide particles without requiring solvent selection, substitution, or other liquid-phase treatments, thereby enhancing both ease of manufacture and adaptability to different application requirements
3Manufacturing precision
If multiple steps are used to manufacture composite particles, then particle composition can be controlled, but manufacturing cost increases
Solution Approach 1:
The patent merges the formation of titanium oxide particles and copper compound coating into a single integrated process. By using sputtering to directly deposit copper compounds onto pre-formed titanium oxide particles in one step, the patent eliminates the need for separate steps involving reducing agents, solvent removal, and subsequent treatments, thereby controlling particle composition while reducing manufacturing cost
Solution Approach 2:
The patent segments the particle formation process into two simple stages: (1) formation of titanium oxide particles with desired size and shape, and (2) direct deposition of copper compounds onto the particle surfaces via sputtering. This segmentation into discrete, controllable steps enables precise composition control without requiring complex multi-step chemical synthesis procedures
4Reliability
If reducing agents are used to reduce divalent copper to monovalent copper, then photocatalytic activity is enhanced, but impurities remain and purification is difficult
Solution Approach 1:
The patent replaces chemical reduction using reducing agents with physical vapor deposition of copper compounds. This substitution eliminates the chemical reduction step that introduces impurities, allowing direct deposition of copper compounds in their desired oxidation state onto titanium oxide particles, thereby achieving both high photocatalytic activity and high purity without additional purification steps
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 efficiently synthesizes composite particles with good fluidity and excellent dispersibility, reducing manufacturing costs and simplifying the process by eliminating the need for liquid phase synthesis.
Implementation Method 1
a thermal plasma evaporation and cooling step of introducing the prepared first and second raw materials into thermal plasma to evaporate the first raw materials
Implementation Method 2
cooling the evaporated first raw materials to generate a composite particle
Data Source
AI summary
A method of manufacturing a composite particle includes: a step of preparing a first raw material including an element selected from any of copper, molybdenum, and silver, and a second raw material including one or more types of elements selected from aluminum, titanium, zirconium, hafnium, iron, yttrium, niobium, tantalum, silicon, calcium, magnesium, tungsten, indium, tin, germanium, nickel, zinc, and molybdenum; and a thermal plasma evaporation and cooling step of introducing the prepared first and second raw materials into thermal plasma to evaporate the first raw materials, and cooling the evaporated first raw materials to generate a composite particle. The composite particle includes the second raw material, and a fine particle carried on a surface of the second raw material and generated from the first raw material having an average particle size of 0.5 nm or more and 300 nm or less.