Composite Vacuum Chamber Wall for Deep Vacuum and Low Weight
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Solution Overview
Problem
Existing vacuum chambers for mass spectrometers face challenges with high weight, low wear resistance, and fragility, leading to leakage issues and inability to achieve deep vacuum due to materials like stainless steel and carbon composites.
Innovation Solution
A vacuum chamber design incorporating a layer of carbon fiber reinforced thermoset with ceramic and aluminum layers, where the ceramic layers provide adhesion and electrical insulation, reducing deformation and leakage while maintaining gas impermeability and durability under high voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-grade stainless steel is used for vacuum chamber, then excellent vacuum characteristics are achieved, but weight becomes high
Solution Approach 1:
The patent employs a composite wall structure consisting of carbon fiber reinforced thermoset material combined with ceramic and aluminum layers. This composite construction provides excellent vacuum characteristics comparable to stainless steel while significantly reducing the overall weight of the vacuum chamber, directly resolving the contradiction between reliability and weight.
2Weight of stationary object
If low weight metals like aluminum are used, then weight is reduced, but wear resistance becomes low leading to deformations
Solution Approach 1:
The patent combines aluminum with ceramic layers and carbon fiber reinforced thermoset material to create a composite structure. The ceramic layers provide wear resistance and structural strength, while the aluminum provides lightweight properties. This composite approach maintains low weight while achieving the necessary wear resistance and structural integrity.
Solution Approach 2:
The patent applies different materials with specific properties to different regions of the wall structure. Ceramic layers are positioned where wear resistance is critical, aluminum is used where weight reduction is prioritized, and carbon fiber reinforced thermoset provides overall structural support. This localized material distribution optimizes both weight and strength characteristics.
3Weight of stationary object
If carbon fiber composites are used for vacuum chamber, then weight is reduced, but the chamber becomes fragile and cannot achieve deep vacuum due to resin release
Solution Approach 1:
The patent uses carbon fiber reinforced thermoset material but combines it with ceramic and aluminum layers to create a more robust composite structure. The ceramic layers prevent resin release into the vacuum environment, while the aluminum provides structural support that reduces fragility. This multi-material composite approach maintains the weight advantages of carbon fiber while eliminating its disadvantages.
Solution Approach 2:
The ceramic layers act as intermediary barriers between the carbon fiber reinforced thermoset and the vacuum environment. These ceramic layers prevent the resin components from releasing into the vacuum, thereby protecting the vacuum quality while allowing the carbon fiber composite to maintain its lightweight structural function.
4Weight of stationary object
If carbon fiber reinforced thermoset is used, then lightweight structure is achieved, but resistance to interior pressures below ambient pressure becomes insufficient
Solution Approach 1:
The patent creates a multi-layer composite wall structure where carbon fiber reinforced thermoset provides the primary lightweight structural support, while ceramic and aluminum layers are added to enhance pressure resistance. The combination of these materials with different mechanical properties creates a composite structure that withstands the pressure differential while maintaining low weight.
Solution Approach 2:
The patent divides the wall into multiple functional layers: carbon fiber reinforced thermoset for lightweight structural support, ceramic layers for wear resistance and pressure containment, and aluminum for additional structural strength. This segmentation of functions across different material layers allows each material to optimize its contribution to pressure resistance while maintaining overall lightweight characteristics.
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 design results in a lightweight, durable, and non-deformable vacuum chamber with improved resistance to interior pressures, capable of achieving deep vacuum conditions and preventing vacuum discharge, suitable for portable and high-vibration applications.
Implementation Method 1
a first layer of ceramic material having a thickness in a range of 40-60 μm... wherein the first layer of ceramic material is positioned between the layer of carbon fiber reinforced thermoset and the layer of aluminum
Implementation Method 2
the ceramic layers provide adhesion and electrical insulation, reducing deformation and leakage while maintaining gas impermeability and durability under high voltage
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to an instrument comprising a vacuum chamber (10), wherein a wall (17) of the vacuum chamber (10) includes a layer of carbon fiber reinforced thermoset (61) having a thickness in a range of 1-10 mm, a first and a second layer of ceramic material (62, 64) having a thickness in a range of 40-60 μm, and a layer of aluminum (63) having a thickness in a range of 0.5-10 mm. The first layer of ceramic material (62) is positioned between the layer of carbon fiber reinforced thermoset (61) and the layer of aluminum (63). The layer of aluminum (63) is positioned between the first layer of ceramic material (62) and the second layer of ceramic material (64). The second layer of ceramic material (64) is positioned most to a side of an interior surface (18) of the wall (17) of the vacuum chamber (10).