Ion Beam Carbonization for Charge Dissipative Polymer Surfaces
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Solution Overview
Problem
Existing methods for imparting charge dissipative properties to dielectric polymer-based materials, such as those used in spacecraft and solar array components, face challenges due to surface irregularities and embedded inorganic particles, which affect the uniformity and effectiveness of ion beam treatments, leading to issues like shadowing and changes in mechanical and electrical properties.
Innovation Solution
A method involving controllable carbonization of surfaces through ion bombardment with a noble gas ion beam and a carbonaceous gas admixture in a vacuum environment, allowing for dynamic surface renewal to achieve uniform charge dissipative properties without altering mechanical or bulk properties, suitable for both flat and grooved surfaces with embedded inorganic particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ion beam treatment is applied to grooved or shaped polymer surfaces, then charge dissipative properties are improved, but treatment uniformity deteriorates due to shadowing effects
Solution Approach 1:
The patent applies dynamic ion beam treatment where the ion beam is scanned across the surface in a controlled manner, allowing uniform treatment of grooved and shaped surfaces by sequentially exposing different areas rather than using a static beam position
Solution Approach 2:
The patent introduces temporal dimension to the treatment process by using time-dependent ion beam scanning patterns, where different regions of the grooved surface are exposed at different times to achieve uniform overall treatment despite the three-dimensional surface topology
2Reliability
If medium- or high-dose ion bombardment is applied to dielectric polymers, then surface conductivity is improved, but surface structural integrity deteriorates due to cross-linking and carbonization
Solution Approach 1:
The patent uses controlled low-dose ion beam treatment that provides sufficient charge dissipative properties without reaching the threshold doses that cause excessive cross-linking and carbonization, achieving the required conductivity while preserving surface structural integrity
Solution Approach 2:
The patent optimizes ion beam treatment parameters including dose, energy, and scanning speed to achieve the optimal balance between inducing charge dissipative conductivity and avoiding excessive structural modifications like carbonization
3Reliability
If ion beam treatment is applied to achieve charge dissipation, then electrical properties are improved, but mechanical properties deteriorate
Solution Approach 1:
The patent applies partial ion beam treatment with controlled low doses that provide adequate charge dissipation while minimizing the cumulative damage to mechanical properties that would occur with higher doses
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 durable charge dissipative surfaces that maintain their properties for extended periods in extreme environments, including geostationary space, with surface resistivity in the required range and stability under thermal cycling, without compromising mechanical or electrical bulk properties.
Implementation Method 1
Ion bombardment of polymers is widely used in the electronic and other device manufacturing industry
Implementation Method 2
Change of many surface properties have been found to be associated with the compositional, structural, and, quite often, morphological surface transformations due to ion bombardment and selective sputtering of the polymers surfaces in vacuum. Some surface reduction due to ion beams sputtering, gaseous atoms migration with the formation of volatile final products and their release from the surface of the polymers in vacuum, i.e. surface depletion of final gaseous products, and, finally, surface carbon content increase (in the bombarded region), as well as simultaneous and subsequent surface structural reconstruction is called 'surface carbonization'.
Implementation Method 3
selective sputtering of the polymers surfaces in vacuum
Data Source
AI summary
A method of manufacturing a charge dissipative surface layer on a member made from or consisting of a dielectric polymeric material or polymer-based composite which is intended to be used in space and other extreme environments, the member having at least one surface, in particular two opposing surfaces, each of the surfaces having a flat or a three-dimensional shape. The method includes carbonizing the at least one surface of the member in a vacuum environment through ion bombardment with simultaneous surface renewal in a dynamic way, by bombardment of the at least one surface with an ion beam formed in a gaseous linear high-current technological ion beam source of rare gas and added predetermined amount of a carbonaceous gas in the same ion beam gas admixture in order to achieve a treated carbonized surface layer with a uniform surface resistivity in a charge-dissipative range.