Layer-by-Layer Nanoparticle Coating for Continuous Fiber Processing

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Solution Overview

Problem

Existing methods for applying pyrolytic-carbon coatings on fibers for ceramic-matrix composites are prone to unevenness and require batch processing, leading to higher fabrication costs and limitations in continuous coating, due to the need for specialized equipment and controlled conditions.

Innovation Solution

A layer-by-layer nanoparticle-deposition method using high-temperature nanoparticles like graphene, applied at ambient conditions, to create multilayered, nanoparticle-coated fibers with controlled ionic charge polarity, allowing for continuous coating and uniform thickness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If chemical vapor deposition (CVD) is used to apply pyC coatings on fibers, then the coatings provide the desired weak interface for CMCs, but the process requires specialized equipment and controlled temperature and pressure conditions

Engineering Contradiction:

Improveinterface qualityVSAvoidequipment requirements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the complex CVD process (which requires specialized equipment, controlled temperature and pressure) with a dip-coating process using nanoparticle suspensions. This substitution eliminates the need for expensive CVD equipment while achieving comparable or superior coating quality through simpler mechanical immersion and drying steps.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fundamental parameters of the coating process by transitioning from gas-phase CVD deposition to liquid-phase nanoparticle suspension coating. This parameter change allows coating to occur at ambient temperature and pressure conditions, eliminating the need for specialized equipment while maintaining coating effectiveness.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If batch processing is used with CVD chambers, then pyC coatings can be applied to fibers, but the length of fiber that may be coated is limited by the size of the CVD chamber

Engineering Contradiction:

Improvecoating qualityVSAvoidcontinuous coating capability

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent enables continuous coating by implementing a dip-coating process where fibers can be continuously fed through coating baths. Unlike batch CVD processing limited by chamber size, the continuous dip-coating method allows unlimited fiber length to be coated continuously, significantly improving productivity while maintaining coating quality.

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If batch processing is used with CVD chambers, then pyC coatings can be applied to fibers, but higher fabrication costs result

Engineering Contradiction:

Improvecoating qualityVSAvoidfabrication cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses inexpensive nanoparticle suspensions in liquid form instead of expensive CVD equipment and chemicals. The dip-coating process employs simple, low-cost materials that can be easily prepared and applied, dramatically reducing fabrication costs while achieving reliable coating quality.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Reliability

If CVD is used to apply pyC coatings, then coatings can be formed on fibers, but the inability to apply these coatings continuously results

Engineering Contradiction:

Improvecoating uniformityVSAvoidcontinuous processing capability

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent transforms the discrete batch CVD process into a continuous dip-coating operation. Fibers are continuously immersed in nanoparticle suspensions and dried, enabling uninterrupted coating production while maintaining uniform coating quality through controlled immersion and drying parameters.

Inventive Principle:

Principle #20Continuity of useful action

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 enables the production of uniformly coated fibers with high-temperature nanoparticles, reducing fabrication costs and eliminating the need for specialized equipment, while allowing for continuous coating and improved composite material strength.

Implementation Method 1

coating a fiber substrate with a first type of nanoparticle to provide a first coated layer of the multilayered, nanoparticle-coated fiber material

Methodology Applied

Scientific EffectLayer-by-layer deposition: Deposition (physical)

Implementation Method 2

coating the surface of each of the plurality of fibers of the fiber substrate with nanoparticles having an ionic charge polarity opposite the ionic charge polarity of the surface of each of the plurality of fibers of the fiber substrate

Methodology Applied

Scientific EffectIonic charge polarity attraction: Electrostatics

Data Source

PatentEP4477634A1Fabricating methods and apparatuses for a multilayered, nanoparticle-coated fiber material

Publication Date: 2024.12.18 THE BOEING CO

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Figure 2A~2B
Figure 2C~2D

AI summary

A fabricating method is provided for a multilayered, nanoparticle-coated fiber material using a layer-by-layer nanoparticle-deposition system. Fabrication includes coating a fiber substrate with a first type of nanoparticle to provide a first coated layer of the multilayered, nanoparticle-coated fiber material. Fabrication also includes coating the first coated layer with a second type of nanoparticle to provide a second coated layer of the multilayered, nanoparticle-coated fiber material.