HARM-Structure Fibrous Network Transfer via Gas Deposition
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Solution Overview
Problem
The manufacturing of individual high aspect ratio molecular structures (HARM-structures) is difficult, time-consuming, and expensive, making it commercially unviable, while networks of these structures are preferable for easier manipulation and integration, but existing methods for transferring them to substrates are complex and costly due to the need for patterning, immediate deposition, and dispersion in liquids which can degrade the product.
Innovation Solution
A method involving the deposition of HARM-structures onto a preliminary substrate from a gas flow, followed by transferring the network to a secondary substrate using a force differential, such as adhesive or electrostatic forces, eliminating the need for liquid dispersion and additional processing steps, and allowing for adjustable thickness, transparency, and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If networks of HARM-structures are produced using prior art methods (filtration, spray coating, spin drying), then the networks can be formed, but the process becomes complex and expensive due to additional processing steps and equipment requirements
Solution Approach 1:
The patent extracts and eliminates the unnecessary intermediate steps of liquid dispersion, sonication, and functionalization that are required in prior art methods. By directly depositing HARM-structures from gas phase onto substrates, the invention removes these complex processing steps while maintaining network formation capability.
Solution Approach 2:
The patent introduces a removable preliminary substrate as an intermediary carrier. HARM-structures are first deposited onto this preliminary substrate, then the entire network is transferred to the final substrate. This intermediary approach simplifies the direct deposition process and enables easy substrate replacement.
2Reliability
If HARM-structures are dispersed in liquid solutions for deposition, then networks can be formed, but the product degrades due to sonication and functionalization requirements
Solution Approach 1:
The patent replaces the mechanical/chemical process of liquid dispersion with direct gas phase deposition. Instead of using liquid carriers that require sonication and functionalization, HARM-structures are deposited directly from the gas phase, eliminating the degrading effects of liquid processing while maintaining network formation.
Solution Approach 2:
The patent changes the physical state parameter from liquid dispersion to gas phase deposition. By transitioning from liquid-based methods to direct gas phase deposition, the invention eliminates the need for sonication and functionalization, thereby preserving product quality while simplifying the manufacturing process.
3Manufacturing precision
If individual HARM-structures are manufactured with well-defined properties, then application performance is optimized, but manufacturing becomes too difficult, time-consuming and expensive for commercial viability
Solution Approach 1:
The patent merges multiple individual HARM-structures into networks or mats that can be manufactured collectively rather than individually. By depositing many structures simultaneously from gas phase onto substrates, the invention achieves commercial-scale productivity while maintaining the well-defined properties of individual components through controlled deposition parameters.
4Manufacturing precision
If networks are deposited directly onto final substrates, then integration is achieved, but patterning becomes difficult and requires additional processing steps
Solution Approach 1:
The patent performs preliminary deposition of HARM-structures onto a preliminary substrate before final substrate attachment. This preliminary action allows for easier patterning and manipulation on the preliminary substrate, after which the entire network is transferred to the final substrate, avoiding the need for complex in-situ patterning on the final substrate itself.
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 method simplifies and reduces the cost of producing fibrous network-substrate components, enabling efficient integration of HARM-structures onto polymer and other substrates, enhancing their conductivity and mechanical properties, and facilitating the production of flexible and transparent electronic devices.
Implementation Method 1
providing a network of fibrous material on a preliminary substrate by depositing high aspect ratio molecular structures (HARM-structures) from gas flow onto the preliminary substrate
Implementation Method 2
applying a force to the network of fibrous material to preferably attract the network of fibrous material from the preliminary substrate to the secondary substrate
Implementation Method 3
transferred onto plastics... by electrical or thermal precipitation
Data Source
AI summary
A method for the production of a fibrous network-substrate component includes the steps of providing a network of fibrous material (1) on a preliminary substrate (2) by filtering high aspect ratio molecular structures (HARM-structures) from gas flow, placing the network of fibrous material (1) on the preliminary substrate (2) in proximity to a secondary substrate (3), applying a force to the network of fibrous material (1) to preferably attract the network of fibrous material (1) from the preliminary substrate (2) to the secondary substrate (3) in order to transfer the network of fibrous material (1) from the preliminary substrate (2) to the secondary substrate (3), and removing the preliminary substrate (2) from the network of fibrous material (1).