Electrostatic Spray Slurry for Controlled Film Microstructure
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Solution Overview
Problem
Existing electrostatic spray deposition methods struggle to maintain the excellent properties of raw materials and control microstructure in the deposited film, leading to unstable droplet generation and poor control over film microstructure.
Innovation Solution
A slurry comprising a solvent, a first polymer dissolved in it, and polymer particles containing a second polymer, where the solvent is a mixed solvent with a Hansen Relative Energy Difference (RED) suitable for selective precipitation of polymer particles, allowing for controlled microstructure formation in the film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a solution made using a raw material is sprayed, then the spraying process can proceed, but it is difficult to maintain the excellent properties of the raw material and control the microstructure in the deposited film
Solution Approach 1:
The patent changes the physical state parameter of the raw material from dissolved solution form to dispersed slurry form containing polymer particles. This parameter change allows the material to be sprayed while maintaining the excellent properties of the raw material and enabling control over the microstructure in the deposited film through particle size and concentration control
Solution Approach 2:
The patent creates a composite slurry system combining polymer particles dispersed in a solvent with specific Hansen Relative Energy Difference characteristics. This composite formulation maintains raw material properties while enabling controlled microstructure formation during electrospray deposition
2Manufacturing precision
If electrospray deposition is performed, then coating film can be formed, but the droplet generation stability is poor and microstructure control is difficult
Solution Approach 1:
The patent changes the slurry composition parameters, specifically using polymer particles with controlled size distribution and concentration in a solvent with specific Hansen Relative Energy Difference. This parameter optimization improves both droplet generation stability during electrospray and microstructure control in the deposited film
Solution Approach 2:
The patent utilizes the dynamic characteristics of the cone-jet spraying mode, where the electrospray process dynamically generates monodisperse droplets from the polymer particle slurry. The dynamic balance between electric field forces and surface tension enables stable droplet generation while maintaining microstructure control
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 enables the formation of films with controlled particle size and pore formation, enhancing the microstructure and properties of the deposited film, allowing for adjustable particle size and porosity.
Implementation Method 1
electrostatic spray deposition is a technique of forming a coating film, in which a high voltage is applied to a fluid injected at a constant flow rate to form microdroplets
Implementation Method 2
the cone-jet mode capable of spraying liquid in droplets having a small particle diameter is the most widely used spraying mode
Implementation Method 3
The first solvent may be a solvent having a Hansen Relative Energy Difference (RED) of less than 1 for the first polymer, and the second solvent may be a solvent having a RED of greater than 1 for the second polymer
Implementation Method 4
The solvent may be a mixed solvent of a first solvent that is a good solvent for the first polymer and a second solvent that is a bad solvent for the second polymer
Implementation Method 5
the microdroplets are deposited on a base material to form the coating film
Data Source
AI summary
A slurry for electrostatic spray deposition and method for forming a coating film using the same are provided. The slurry comprises a solvent, a first polymer dissolved in the solvent, and polymer particles containing a second polymer and dispersed in the solvent.