Electro-Flow Focusing Deposition for High-Conductivity Substrates
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Solution Overview
Problem
Existing methods for depositing substances with high conductivity on a substrate, such as patches, face limitations in flow rate and yield, and require additional drying steps, which are not suitable for industrial applications.
Innovation Solution
A method utilizing electro-flow focusing technique to generate electrically charged droplets from a conducting spraying nozzle, applying an electric field and compressed gas to improve deposition yield and eliminate the need for drying steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electrohydrodynamic spraying (electrospray) is used to deposit substance on patch, then deposition accuracy is maintained, but flow rate is limited especially for high conductivity formulations
Solution Approach 1:
The patent combines electrospray technology with flow focusing technology to create a hybrid deposition system. The electrospray component maintains deposition accuracy through electric field control, while the flow focusing component enables higher flow rates by using compressed gas to focus and propel the liquid formulation through a capillary, thus resolving the contradiction between productivity and reliability
Solution Approach 2:
The invention uses a composite approach by integrating two different physical mechanisms (electrical field control from electrospray and gas-driven flow focusing) into a single deposition system. This composite methodology allows the system to achieve both high flow rates and precise deposition control that neither technique could achieve alone, particularly for high conductivity formulations
2Ease of manufacture
If conventional deposition methods are used, then manufacturing process is simple, but additional drying steps are required which are not suitable for industrial applications
Solution Approach 1:
The patent utilizes the phase transition of liquid to aerosol droplets through the combined electrospray and flow focusing mechanisms. This phase transition creates fine mist deposition that dries rapidly upon contact with the patch substrate, eliminating the need for separate drying steps and making the process suitable for industrial manufacturing while maintaining simplicity
3Quantity of substance
If liquid formulation with high conductivity is used, then therapeutic substance delivery is improved, but deposition yield decreases with conventional methods
Solution Approach 1:
The patent applies pneumatic principles by using compressed gas flow to focus and propel the high conductivity liquid formulation through the capillary and onto the patch. This gas-driven flow focusing mechanism overcomes the limitations of electrospray alone with high conductivity liquids, maintaining high deposition yield while enabling the use of therapeutically important high conductivity formulations
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 method achieves improved deposition yield and accuracy for high conductivity substances without additional drying, suitable for industrial manufacturing.
Implementation Method 1
by providing an electric field downstream of the outlet of the spraying nozzle
Implementation Method 2
by providing compressed gas around the liquid composition flowing out of the outlet of the spraying nozzle
Implementation Method 3
collecting the generated liquid droplets on the substrate
Data Source
AI summary
The invention relates to a method of depositing a substance onto a substrate (6), comprising: —providing a substrate (6) at a distance from a conducting spraying nozzle (1), said spaying nozzle (1) having an outlet (2); —providing a liquid composition containing the substance to the spraying nozzle (1); —generating electrically charged liquid droplets from the liquid composition between the outlet (2) of the spraying nozzle (1) and the substrate (6), by providing compressed gas around the liquid composition flowing out of the outlet (2) of the spraying nozzle (1) and by providing an electric field downstream of the outlet (2) of the spraying nozzle (1); and—collecting the generated liquid droplets on the substrate (6). The invention also relates to an installation for carrying out this method.