Micro Coil Manufacturing via Lateral Gas Flow Inversion

Solution Overview

Problem

Conventional manufacturing apparatuses for coil-shaped carbon fibers face issues with gas flow and catalyst contact, leading to low yield and purity, and difficulties in stacking reaction containers due to the perpendicular orientation of inlet and outlet, restricting thermal decomposition and catalyst reactions.

Innovation Solution

The manufacturing method involves introducing source gases from one lateral direction into a cylindrical reaction container, allowing smooth flow and reaction with the catalyst, and includes a substrate with a catalyst layer on its outer surface, enabling efficient growth and production of micro coils. The source gas introduction and discharge pipes are oriented in opposite directions, facilitating efficient gas flow and allowing for easy stacking of reaction containers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the inlet extends upward from the upper portion of the reaction container in the perpendicular direction, then the source gas can be introduced into the reaction container, but the flow of source gas and contact with the catalyst inside the reaction container is restricted, leading to low yield and purity

Engineering Contradiction:

Improvesource gas introductionVSAvoidyield and purity of micro coils

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent inverts the conventional inlet orientation by extending the inlet horizontally from the lateral surface of the reaction container rather than vertically from the upper portion. This inversion allows source gas to flow horizontally through the reaction container, significantly improving contact with the catalyst and increasing yield and purity of micro coils.

Inventive Principle:

Principle #13The other way round (Inversion)

2Ease of operation

If the inlet extends upward from the upper portion of the reaction container in the perpendicular direction, then the source gas can be introduced into the reaction container, but thermal decomposition and catalyst reactions hardly occur inside the reaction container

Engineering Contradiction:

Improvesource gas introductionVSAvoidthermal decomposition reaction and catalyst reaction efficiency

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent inverts the conventional inlet orientation by extending the inlet horizontally from the lateral surface of the reaction container rather than vertically from the upper portion. This inversion allows source gas to flow horizontally through the reaction container, significantly improving contact with the catalyst and increasing yield and purity of micro coils.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If the inlet extends upward from the upper portion of the reaction container and the outlet extends downward from the lower portion, then gas flow can be established, but it is difficult to stack a plurality of reaction containers in the up and down directions, restricting massive production

Engineering Contradiction:

Improvegas flow establishmentVSAvoidmassive production capability

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent inverts the conventional inlet orientation by extending the inlet horizontally from the lateral surface of the reaction container rather than vertically from the upper portion. This inversion allows source gas to flow horizontally through the reaction container, significantly improving contact with the catalyst and increasing yield and purity of micro coils.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the gas flow direction from the vertical dimension to the horizontal dimension by extending the inlet and outlet horizontally from the lateral surfaces. This dimensional change enables vertical stacking of multiple reaction containers while maintaining effective gas flow and catalyst contact in each container, thereby enabling massive production.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 approach enhances the yield and purity of micro coils by ensuring effective gas flow and catalyst interaction, enabling efficient and massive production while allowing for easy stacking of reaction containers.

Implementation Method 1

when the source gas is supplied from the inlet while the reaction container is heated to a predetermined temperature by a heater, the source gas flows into the reaction container downward, and is pyrolized or thermally decomposed inside the reaction container

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Implementation Method 2

a carbon fiber which grows in a gas phase under the thermally decomposed source gas grows from a substrate which is received inside the reaction container while coating a metal catalyst on the substrate

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentEP2597068B1Micro coil manufacturing method and manufacturing device thereof

Publication Date: 2015.02.18 CMC ADVANCED R&D CO LTD

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AI summary

A reaction container 20 includes a cylindrical container body 20a, a source gas introduction pipe group 20b-20d and a gas discharge pipe group 20f extended in the opposite directions from both left and right side portions of the container body 20a, and a cylindrical substrate 30 inserted into the container body 20a. Source gases introduced from the source gas introduction pipe group 20b-20d into the container body 20a are thermally decomposed by the reaction with a catalyst carried on the substrate 30 at a predetermined high temperature to grow micro coils from the substrate 30.