Mesh Nebulizer Surface Coating for Stable Surface Energy
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Solution Overview
Problem
Existing surface treatments for mesh nebulizers fail to maintain consistent surface energy over time, with hydrophobic coatings hydrolyzing and hydrophilic coatings losing their properties due to exposure to fluids and contaminants.
Innovation Solution
A method involving the deposition of a metal surface layer followed by a hydrophobic coating layer, which can be selectively removed to expose a hydrophilic surface, and optionally a polymeric coating layer, using materials like silver, gold, and organo-silicon or organophosphorus acid-based coatings to stabilize surface energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydrophobic coatings are applied to mesh nebulizer surfaces, then surface energy is reduced and fluid repellency is improved, but the coatings hydrolyze over time and surface energy increases
Solution Approach 1:
The patent applies a multi-layer composite coating system consisting of a hydrophobic outer layer and a hydrophilic inner layer on the mesh nebulizer surface. This composite structure combines the benefits of both hydrophobic and hydrophilic properties, where the hydrophobic layer provides initial fluid repellency and the hydrophilic layer maintains long-term stability by preventing hydrolysis of the outer layer, thus resolving the contradiction between initial performance and long-term durability.
Solution Approach 2:
The patent modifies the surface energy parameters of the mesh nebulizer by applying coatings with specific contact angle ranges (hydrophobic: 90-150°, hydrophilic: 0-90°). This controlled parameter change allows optimization of both fluid repellency and stability, addressing the contradiction between achieving low surface energy and maintaining it over time.
2Reliability
If hydrophilic coatings are applied to mesh nebulizer surfaces, then surface energy is increased and fluid wettability is improved, but the hydrophilic components dissolve in water and surface energy decreases
Solution Approach 1:
The patent uses a composite coating structure where a hydrophobic outer layer protects the hydrophilic inner layer from direct contact with water and dissolving. The hydrophilic layer remains intact beneath the protective hydrophobic layer, maintaining its surface energy properties without dissolving, thus resolving the contradiction between improved wettability and prevention of component loss.
Solution Approach 2:
The hydrophobic outer layer acts as a preliminary protective barrier that prevents water and dissolved substances from reaching and dissolving the hydrophilic inner layer. This preliminary anti-action against dissolution preserves the hydrophilic components and maintains consistent surface energy over time.
3Ease of operation
If surface treatments are applied to alter surface energy, then fluid flow control is improved, but the treatments fail to retain consistent surface energy when exposed to surfactants and biological compounds
Solution Approach 1:
The dual-layer composite coating (hydrophobic outer + hydrophilic inner) provides robust surface energy retention when exposed to surfactants and biological compounds. The layered structure creates a more stable surface that resists adsorption and chemical interaction, maintaining consistent fluid flow control properties even in challenging environments with proteins, enzymes, and other biological materials.
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 provides mesh nebulizers with stable surface energy resistance to environmental attacks, ensuring consistent fluid flow and droplet formation over time, even when exposed to surfactants and biological compounds.
Implementation Method 1
depositing a metal surface layer on surfaces of the components
Implementation Method 2
forming a hydrophobic coating layer comprising an organo-silicon or a self-assembled monolayer of an organophosphorus acid
Implementation Method 3
removing select areas of the hydrophobic coating layer to expose the metal surface layer
Implementation Method 4
surface tensions of fluids and substrates (reservoirs, channels, pores, etc.) must be balanced in order to maintain consistent fluid flow
Data Source
Figure 1~2B
Figure 3A~4A
Figure 4B~4D
AI summary
Methods of altering the surface energy of components of a mesh nebulizer are provided, comprising: a) depositing a metal surface layer on surfaces of the component; b) forming a hydrophobic coating layer comprising an organo-silicon or a self- assembled monolayer of an organophosphorus acid directly on the metal surface layer or indirectly on the metal surface layer through an intermediate organometallic coating; and either: i) removing select areas of the hydrophobic coating layer to expose the metal surface layer; or ii) forming a polymeric coating layer chemically bonded to and propagated from terminal functional groups on the hydrophobic coating layer that are capable of initiating polymer growth when exposed to a source of polymerizable monomer, on select areas of the components. Mesh nebulizers formed by such methods are also provided.