Nano Carbon Coating from Disaccharide Colloid for Uniform Bonding
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Solution Overview
Problem
Existing methods for nano carbon coating of microcellular substances are costly, inefficient, and result in weak substrate-nano carbon bonds with potential segregation, making uniform coating difficult.
Innovation Solution
A method involving the preparation of a colloid liquid from disaccharide derivatives, which are heated to specific temperature ranges to form nano carbon particles, followed by substrate impregnation and sintering in controlled atmospheres to create a strong nano carbon coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coal particles are ground into fine powder and suspended in liquid medium for coating, then the coating can be applied to microcellular substances, but the bond between substrate and nano-carbon is weak and segregation occurs
Solution Approach 1:
The patent uses binding additives as intermediary substances between the coal powder and microcellular substrate. These additives create stronger chemical or physical bonds that prevent segregation and improve adhesion, resolving the contradiction between ease of manufacture and bond strength reliability.
Solution Approach 2:
The patent creates a composite coating system combining coal powder, binding additives, and liquid medium. This composite approach allows the different components to work together, with the binding additives providing the necessary adhesion while the coal provides the carbon coating, thus achieving both manufacturability and reliability.
2Manufacturing precision
If nano carbon powder is used for coating, then the coating can be applied to microcellular substances, but the nano-carbon powder can obstacle the cellular microstructure
Solution Approach 1:
The patent applies coating only to the external surface of the microcellular substance rather than impregnating the internal structure. This localized approach ensures uniform coating coverage while preserving the integrity of the cellular microstructure inside, resolving the contradiction between manufacturing precision and shape integrity.
3Reliability
If disaccharide derivatives are thermally treated to produce clean carbon, then the carbon quality is high, but the production cost is expensive
Solution Approach 1:
The patent replaces expensive disaccharide derivatives with cheaper coal powder as the carbon source. While coal requires additional processing steps, the raw material cost is significantly lower, making the overall process more economical while still achieving acceptable carbon coating quality for the intended application.
Solution Approach 2:
The patent changes the carbonization parameters by using coal powder that is ground to specific particle size ranges and carbonized at controlled temperatures. This allows optimization of the balance between carbon quality and production cost, achieving sufficient cleanliness without the high expenses of disaccharide-based methods.
4Manufacturing precision
If coal is ground into nanoparticles, then the coating can be applied effectively, but the grinding process is particularly costly
Solution Approach 1:
The patent uses coal powder ground to a fine but not ultra-fine nanoparticle level. This partial action approach provides sufficient dispersion and coating effectiveness for microcellular substances without incurring the excessive costs of producing true nanoparticles, optimizing the balance between manufacturing precision and ease of manufacture.
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
Achieves an economical and uniform nano carbon coating with strong substrate bonds, preventing segregation and providing a stable, non-flammable coating suitable for various applications.
Implementation Method 1
a disaccharide derivatives is heated to a first temperature range to lose its crystal water content
Implementation Method 2
heating the disaccharide derivative to a second temperature range, in which the disaccharide derivative is carbonized
Implementation Method 3
the nano carbon particles are formed by dehydration of the melted and carbonized disaccharide derivatives... the lower the temperature difference between the carbonized disaccharide and the steam (water), the faster the dissolution of the nano carbon and the formation of the colloidal liquid
Implementation Method 4
The invention also discloses a method of carbonating a substrate comprising the step of coating the substrate with the above-described colloid liquid and the step of sintering the substrate
Data Source
AI summary
The invention discloses a method of preparing a colloid liquid for carbonization, comprising the following steps: - Heating a disaccharide derivative to a first temperature range, in which the disaccharide derivative melts; - Heating the disaccharide derivative to a second temperature range, in which the disaccharide derivative is carbonized, wherein the temperature of the second temperature range is higher than the temperature of the first temperature range; and - Directing a superheated stream on the disaccharide derivative; and a method of carbonating a substrate comprising the following steps: - Coating the substrate with the colloid liquid; and - Sintering the substrate.