Concentric Magnetic Layering on 3D Templates for Property Control

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Solution Overview

Problem

Existing methods for manufacturing magnetizable components at micro- and nanoscales lack precision in controlling physical properties such as saturation magnetization and surface area enhancement, particularly in generating high aspect ratio three-dimensional patterns effectively.

Innovation Solution

The method involves patterning substrates with columnar arrays using two-photon polymerization and subsequent electroplating and vacuum chamber-based deposition techniques to create concentrically layered magnetizable components with controlled micro- or nanoscale properties, utilizing iron and iron nitride compositions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of moving object

If two-photon polymerization is used to generate high aspect ratio three-dimensional patterns, then surface area enhancement is achieved, but manufacturing precision of magnetic properties is insufficient

Engineering Contradiction:

Improvesurface areaVSAvoidmagnetic properties control

Core Design Contradiction:

Area of moving objectVSManufacturing precision

Solution Approach 1:

The manufacturing process is segmented into distinct sequential steps: first creating the three-dimensional patterned substrate, then depositing multiple concentric layers of different materials (magnetic, non-magnetic, conductive, insulating) in separate deposition cycles. This segmentation allows each layer to be precisely controlled independently, achieving both high surface area and precise magnetic property control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The three-dimensional patterned substrate is created in advance using two-photon polymerization before the magnetic layers are deposited. This preliminary action establishes the high surface area geometry, which then serves as the foundation for subsequent precise material deposition that controls the magnetic properties.

Inventive Principle:

Principle #10Preliminary action

2Area of moving object

If micro- and nanoscale patterning is applied to increase surface area, then surface area enhancement is achieved, but precision in controlling saturation magnetization and Curie temperatures is insufficient

Engineering Contradiction:

Improvesurface areaVSAvoidsaturation magnetization and Curie temperatures control

Core Design Contradiction:

Area of moving objectVSManufacturing precision

Solution Approach 1:

The invention uses composite structures with multiple concentric layers of different materials (magnetic layers, non-magnetic layers, conductive layers, insulating layers) deposited on the patterned substrate. By controlling the composition, thickness, and arrangement of these composite layers, precise control over saturation magnetization and Curie temperatures is achieved while maintaining high surface area enhancement.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention controls magnetic properties by changing material parameters including layer thickness, material composition, and layer sequence. By adjusting these parameters during the deposition process, precise control over saturation magnetization and Curie temperatures is achieved while maintaining the high surface area geometry.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If conventional patterning methods are used, then manufacturing simplicity is maintained, but the ability to generate high aspect ratio three-dimensional patterns is insufficient

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidhigh aspect ratio three-dimensional patterns

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The invention replaces conventional mechanical or chemical patterning methods with two-photon polymerization, an optical-based technique that uses focused laser light to selectively polymerize photosensitive material. This substitution enables the creation of complex high aspect ratio three-dimensional patterns that cannot be achieved with traditional mechanical patterning methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 precise control of physical properties and surface area enhancement, allowing for the production of magnetizable components with tailored magnetic properties and increased surface area, suitable for applications ranging from small to large scales.

Implementation Method 1

patterning substrates with columnar arrays using two-photon polymerization

Methodology Applied

Scientific EffectTwo-photon polymerization: Photopolymerisation

Implementation Method 2

sequential electroplating and vacuum chamber-based deposition techniques

Methodology Applied

Scientific EffectElectroplating: Electroplating

Implementation Method 3

vacuum chamber-based deposition techniques

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Implementation Method 4

utilizing iron and iron nitride compositions

Methodology Applied

Scientific EffectFerromagnetism: Ferromagnetism

Implementation Method 5

utilizing iron and iron nitride compositions

Methodology Applied

Scientific EffectNitriding: Nitriding

Data Source

PatentUS20240183053A1Apparatus and method for manufacturing magnetizable components consisting of concentrically layered materials grown using patterned substrate seed templates

Publication Date: 2024.06.06 WEINBERG MEDICAL PHYSICS INC

AI summary

Methods and systems are provided for patterning surfaces, generating templates from the patterned surfaces, then using those templates to manufacture magnetizable components with micro- or nanoscale control over the physical properties of the component.