Enamel Electrode Assembly for DBD Plasma Sources
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Solution Overview
Problem
Conventional dielectric barrier discharge (DBD) plasma sources face challenges in maintaining operational lifetime and size due to electric breakdown issues, especially in surface DBD plasma sources with embedded electrodes, where the electric field strength varies, and the brittleness of ceramic materials limits the size of commercial plasma sources.
Innovation Solution
An electrode assembly using an enamel layer with embedded electrodes, where the enamel layer is constructed by successively depositing and fusing thin layers of powdered glass to increase electric breakdown strength, particularly near the plasma generating surface, allowing for larger-sized DBD plasma sources and improved thermal expansion matching, and enabling the use of thinner layers for enhanced robustness and cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dielectric layer is used in surface DBD plasma sources with embedded electrodes, then plasma generation is enabled, but electric breakdown occurs reducing operational lifetime
Solution Approach 1:
The patent uses a composite structure consisting of a metal base plate and an enamel layer. The enamel layer, deposited on the metal substrate, provides superior dielectric properties and electric breakdown resistance compared to conventional ceramic materials, thereby extending operational lifetime while preventing electric breakdown in surface DBD plasma sources with embedded electrodes.
Solution Approach 2:
The patent changes the material parameter from conventional ceramic to enamel coating on metal. This material substitution fundamentally alters the dielectric strength, thermal conductivity, and mechanical properties of the dielectric layer, enabling it to withstand higher electric fields and thermal stresses without breakdown, thus improving reliability.
2Reliability
If ceramic materials are used for dielectric layers, then electric breakdown resistance is improved, but brittleness limits the size of plasma sources
Solution Approach 1:
The patent replaces brittle ceramic materials with a composite structure of metal base plate and enamel layer. The metal substrate provides mechanical strength and ductility, allowing the plasma source to be manufactured in larger sizes without the dimensional constraints imposed by ceramic brittleness, while the enamel layer maintains superior electric breakdown resistance.
Solution Approach 2:
The patent fundamentally changes the mechanical and electrical parameters of the dielectric layer by using enamel on metal instead of ceramic. This enables larger dimensions while maintaining breakdown resistance, as the metal substrate eliminates the brittleness constraint that limited the size of ceramic-based plasma sources.
3Stability of the object's composition
If enamel layer is used instead of ceramic, then thermal expansion matching is improved, but manufacturing complexity increases
Solution Approach 1:
The patent changes the thermal and mechanical parameters of the dielectric structure by using enamel on metal. The metal substrate's thermal expansion properties can be selected to match the enamel layer, creating a thermally stable composite that avoids the cracking and delamination issues common in ceramic-enamel systems, thereby improving compositional stability.
Solution Approach 2:
The composite structure of metal and enamel allows independent optimization of thermal expansion properties. The metal substrate can be chosen to match the thermal expansion of the enamel, creating a stable bonded structure. While the deposition process adds a step, it eliminates the need for complex ceramic processing and firing cycles, potentially simplifying overall manufacturing.
4Reliability
If thicker dielectric layers are used, then electric breakdown strength is improved, but cooling efficiency decreases
Solution Approach 1:
The patent uses a composite structure where a thin enamel layer (providing sufficient dielectric strength) is deposited on a metal substrate (providing superior thermal conductivity). This allows the dielectric layer to be thinner while maintaining breakdown strength, and the metal substrate efficiently conducts heat away from the plasma generation zone, improving cooling efficiency compared to thick ceramic layers.
Solution Approach 2:
The patent changes the thermal conductivity parameter of the dielectric structure by using metal as the substrate. This allows for thinner dielectric layers with adequate breakdown strength while achieving superior heat dissipation through the metal, thereby improving cooling efficiency without sacrificing electrical insulation performance.
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 solution enables the manufacture of DBD plasma sources with plasma generation surfaces exceeding one meter in size, with increased operational lifetime and power density, while maintaining robustness and reducing the risk of electric breakdown, as demonstrated by withstanding higher voltages and maintaining functionality over extended periods.
Implementation Method 1
the enamel layer is constructed by successively depositing and fusing thin layers of powdered glass
Implementation Method 2
successively depositing and fusing thin layers of powdered glass
Implementation Method 3
which gives rise to ionization of gas present at the surface of the dielectric layer thus generating the plasma
Implementation Method 4
fusing each one of the plurality of second layers of powdered glass by heating
Data Source
Figure 1a~1c
Figure 2~2a
Figure 3
AI summary
An electrode assembly for use in a dielectric barrier discharge plasma source comprises a base metal plate, an enamel layer on a surface of the base metal plate and embedded electrodes embedded in the enamel layer. The electrode assembly may be made by depositing a one or more layers of powdered glass over a surface of the base metal plate, fusing the powdered glass the one or more layers each in a separate heating step for the relevant layer. To form the embedded electrodes, a pattern of electrode material is provided over the powdered glass of the one or more layers after fusing the one or more layers. Subsequently one or more further layers of powdered glass are deposited over the electrodes and the layer(s) below it, and the powdered glass in each of the one or more further layers is fused in a separate heating step.