Dual Feed Cold Spray Nozzle for Composite Film Control
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Solution Overview
Problem
Conventional cold-spray deposition techniques face challenges in efficiently co-depositing particles with differing physical properties, leading to mismatched deposition efficiencies and poor control of film composition, which limits high-volume manufacturing of composite films with improved thermal management and warpage control.
Innovation Solution
The implementation of multiple independent material delivery systems with separate temperature and feed rate controls for solid powder materials, allowing for independent heating and positioning, and a nozzle design with convergent and divergent sections to optimize the deposition of materials with varying properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional cold-spray deposition techniques are used to co-deposit particles with differing physical properties, then the deposition process is simple, but the deposition efficiency mismatches and film composition control is poor
Solution Approach 1:
The feeding system is segmented into multiple independent feeding mechanisms, each capable of delivering different powder materials to the nozzle at controlled rates. This segmentation allows independent control of each material's feed rate, enabling precise composition control of the deposited film while maintaining manageable system complexity through modular design
Solution Approach 2:
The system employs dynamic control of feed rates for different materials, allowing real-time adjustment of each material's delivery rate independent of others. This dynamic capability enables optimization of deposition efficiency for each material type while maintaining overall film composition precision through continuous parameter adjustment
2Manufacturing precision
If a layer-by-layer approach is used to deposit films with vastly different components, then film composition control is improved, but the manufacturing throughput is reduced and adhesion risks increase
Solution Approach 1:
Multiple materials are merged and delivered simultaneously through the single nozzle, combining the composition control benefits of layered approaches with the throughput advantages of continuous deposition. The independent feeding systems allow different materials to be deposited together in a single continuous process, eliminating the need for repeated loading and sequential layer deposition
Solution Approach 2:
The system enables continuous deposition of composite films with varying compositions without interruption or material replacement. The multiple feeding systems operate continuously, delivering different materials in controlled amounts throughout the deposition process, thereby maintaining high throughput while preserving film composition precision
3Ease of manufacture
If multiple materials are treated together in the cold-spray nozzle, then the process is simplified, but different deposition efficiencies result in poor film composition control
Solution Approach 1:
The feeding system is segmented into multiple independent channels, each controlling the delivery of specific materials to the nozzle. This segmentation maintains process simplicity by keeping each material's delivery path separate and controlled, while enabling precise composition control through independent adjustment of each channel's feed rate
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 efficient and controlled deposition of composite films with graded compositions, improving end-product quality and throughput, allowing for high-volume manufacturing of films with enhanced thermal management and reduced warpage.
Implementation Method 1
a heater to heat the solid powder material
Implementation Method 2
cold-spray deposition
Implementation Method 3
spray the carrier fluid and the heated solid powder material out of the divergent section
Data Source
AI summary
Cold-spray nozzles, systems, and techniques are described herein related to manufacturing implementations of efficient film deposition. A deposition system includes multiple feed systems to deliver solid powder materials at controlled feed rates and temperatures, and a nozzle, including convergent and divergent sections and connections to the feed systems, to receive a carrier fluid in the convergent section and to spray the carrier fluid and the solid powder materials out of the divergent section. A nozzle includes multiple ports to receive solid powder materials for admission into a carrier fluid, with one or more ports in the convergent section and one or more ports in the divergent section. A method may include delivering a carrier fluid to a nozzle, heating multiple solid powder materials, delivering these solid powder materials to the nozzle, and spraying the solid powder materials out of a divergent section of the nozzle.