Nano Silver Thin Film Spray Apparatus for Uniform Coating
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Solution Overview
Problem
Conventional methods for manufacturing silver-coated surfaces, such as reflection plates, face issues with low deposition uniformity and reduced reflectivity due to non-uniform silver film thickness, leading to increased wastewater treatment costs and decreased productivity, particularly in solar energy applications where high reflectivity is crucial.
Innovation Solution
A silver thin-film spread apparatus using nano metallic silver deposition with a treatment booth, transfer device, spray device, and rotation device to ensure uniform deposition of nano silver thin films on substrates of varying shapes, maintaining constant temperature and humidity, and using a two-headed spray gun with high-pressure air and solution supply for precise film formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional plating method is used to form silver film on resin molded articles, then metallic appearance is achieved, but wastewater treatment problems occur and environmental control requirements increase
Solution Approach 1:
The invention changes the chemical state of silver from ionic (in conventional plating solutions) to metallic nanoparticle form. By using colloidal silver suspension instead of traditional plating chemicals, the process achieves metallic coating without generating hazardous wastewater requiring treatment facilities.
Solution Approach 2:
The invention uses a disposable colloidal silver suspension that can be sprayed and dried without complex recovery systems. The nano silver particles are applied in a simple spray-drying process that eliminates the need for wastewater treatment infrastructure, making the process economically viable.
2Ease of manufacture
If conventional vacuum deposition device is used to provide metallic appearance, then luxurious appearance is achieved, but investment in wastewater treatment facilities and increased facility size decrease productivity
Solution Approach 1:
The invention uses a spray device that delivers colloidal silver suspension onto the substrate through pneumatic spraying. The suspension is then dried to form a uniform metallic coating. This spray-drying method is simpler and faster than vacuum deposition, eliminating the need for large vacuum chambers and complex equipment.
Solution Approach 2:
The invention replaces the complex mechanical vacuum deposition system with a simple spray-drying process. Instead of using vacuum pumps, heating elements, and precise thickness control mechanisms, the patent uses aerosol spraying followed by drying, dramatically simplifying the equipment and improving productivity.
3Ease of manufacture
If conventional reflection plate manufacturing method is used with sprayed mixed solution, then silver film is deposited on glass surface, but deposition uniformity is low and reflectivity decreases
Solution Approach 1:
The invention changes the physical state and size of silver particles from large ionic compounds in mixed solutions to ultra-fine nanoparticulate colloidal suspension. The small particle size (1-100 nm) and uniform distribution in the colloidal medium enable even spray deposition and uniform film formation with high reflectivity.
Solution Approach 2:
The invention uses a controlled spray process that deposits a thin, uniform layer of colloidal silver particles. By controlling the spray parameters and using the fine nanoparticle suspension, the process achieves uniform coverage without excessive material application, ensuring consistent film thickness and high reflectivity across the entire substrate surface.
4Ease of manufacture
If conventional plating method is used for reflection plate manufacturing, then silver film is formed, but film thickness uniformity cannot be controlled and light reflection is reduced
Solution Approach 1:
The invention changes the silver material from bulk or ionic form to nanoparticulate colloidal suspension. The small particle size and high surface area to volume ratio of the nano silver particles enable formation of thin, uniform films with excellent optical properties. The uniform particle distribution ensures consistent light reflection across the film.
Solution Approach 2:
The invention uses a composite colloidal suspension containing silver nanoparticles dispersed in a carrier liquid. This composite material provides uniform particle distribution and controlled deposition, resulting in films with superior optical uniformity and light reflection properties compared to conventional plating methods.
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
Enhances film compactness and coating uniformity, improving reflectivity and energy production capacity in solar systems by minimizing light loss and automating the nano silver thin film formation process, resulting in higher manufacturing efficiency and cost competitiveness.
Implementation Method 1
a spray device formed at an upper side of the treatment booth for spraying silver solution on a surface of the substrate
Implementation Method 2
a rotation device formed at the lower side of the treatment booth for rotating the substrate
Implementation Method 3
a moving device for linearly reciprocating the spray device
Data Source
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AI summary
Disclosed is a silver thin film spread apparatus by means of deposition of nano metallic silver, the apparatus including a treatment booth formed at one side with an inlet for inputting a substrate, and formed at the other side with an outlet for discharging the substrate, a transfer device formed at a lower side of the treatment booth for transferring the substrate, a spray device formed at an upper side of the treatment booth for spraying silver solution on a surface of the substrate, a moving device for linearly reciprocating the spray device, and a rotation device formed at the lower side of the treatment booth for rotating the substrate, whereby reflectivity can be enhanced by increasing film compactness and coating uniformity of thin film, where the substrate is rotated at a predetermined constant speed to allow the spray guns to linearly reciprocate and to allow the nano silver thin film to be uniformly spread and deposited on the surface of the substrate at a predetermined constant frequency.