Nanostructured Materials via Spark Ablation Gas Flow

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for producing nanostructured materials on porous carriers result in anisotropic deposition, limiting the coverage and control of nanoparticles on both external and internal surfaces, whereas achieving an essentially isotropic distribution is crucial for applications like catalysis and sensing.

Innovation Solution

A method involving the use of a spark ablation device to produce and deposit nanoparticles in a gas flow, ensuring even distribution on both external and internal surfaces of porous carriers by controlling particle size, concentration, and residence time, with parameters like spark energy, frequency, and gas flow rate, allowing for high diffusivity and efficient deposition at low temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If physical vapor deposition (PVD) method is used to deposit nanoparticles onto porous carriers, then controlled growing of matter onto external surfaces is achieved, but penetration into the porous carrier is limited and anisotropic deposition occurs

Engineering Contradiction:

Improvecontrolled growing of matterVSAvoidpenetration into porous carrier

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The patent changes the deposition parameters by using a spark ablation source that generates nanoparticles in a gaseous state, followed by condensation in a controlled atmosphere. This allows the nanoparticles to be transported as a gas flow through the porous carrier, enabling penetration into internal surfaces while maintaining controlled deposition. The key parameter change is transitioning from direct vapor deposition to nanoparticle generation and subsequent condensation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces a gaseous intermediary medium that carries the nanoparticles generated by spark ablation. This gas flow serves as a mediator to transport nanoparticles deep into the porous carrier structure, overcoming the limitation of direct PVD methods where matter cannot penetrate into internal surfaces. The gas flow enables isotropic distribution throughout the porous matrix.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If impregnation with nanoparticle-containing liquids is used, then deposition onto porous carriers is achieved, but control for production of nanostructured materials with desired morphology is insufficient

Engineering Contradiction:

Improvedeposition onto porous carriersVSAvoidcontrol of nanostructured material morphology

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent utilizes phase transitions by generating nanoparticles in a gaseous state through spark ablation, then controlling their condensation and deposition. This phase change approach allows precise control over nanoparticle formation, size, and distribution, enabling accurate morphology control of the resulting nanostructured materials while maintaining ease of deposition onto porous carriers.

Inventive Principle:

Principle #36Phase transitions

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 nanostructured materials with a fractal-like structure, ensuring even nanoparticle distribution on the scale of pore size, enhancing surface area and application efficiency in catalysis and sensing without requiring vacuum conditions.

Implementation Method 1

A method involving the use of a spark ablation device to produce and deposit nanoparticles in a gas flow

Methodology Applied

Scientific EffectSpark ablation: Electric Spark

Implementation Method 2

transporting the nanoparticles into, and optionally through, a porous carrier by a gas flow

Methodology Applied

Scientific EffectGas flow transport: Convection

Implementation Method 3

ensuring even distribution on both external and internal surfaces of porous carriers by controlling particle size, concentration, and residence time, with parameters like spark energy, frequency, and gas flow rate, allowing for high diffusivity

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 4

depositing the nanoparticles onto the surface of said porous carrier in an essentially isotropic manner

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS11512382B2Production of nanostructured materials

Publication Date: 2022.11.29 VSPARTICLE HLDG BV

AI summary

The invention relates to a method for the production of materials. In particular the invention relates to nanostructured materials, and an apparatus and method for the production thereof. In accordance with the invention, nanostructured materials are produced by the subsequent steps of producing nanoparticles; transporting the nanoparticles into, and optionally through, a porous carrier by a gas flow; and depositing the nanoparticles onto the surface of said porous carrier in an essentially isotropic manner.