Nanotube Composite Coatings for Controlled Density and Thick Films

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Solution Overview

Problem

Current methods for forming nanotube fabric layers over substrates lack control over nanotube volume density and require multiple spin coat processes to achieve significant thickness, which is inefficient and costly.

Innovation Solution

A method involving a composite article comprising a mixture of carbon nanotubes and nanoscopic particles in a predefined ratio, deposited via spin coating, allowing for controlled nanotube volume density and thick film formation in a single process, using processes like solubilization, filtration, and pH adjustment to create a stable colloidal system.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional spin coating methods are used to form nanotube fabric layers, then the layers can be deposited on substrates, but control over nanotube volume density is lacking and multiple spin coat processes are required to achieve significant thickness

Engineering Contradiction:

Improvenanotube volume density controlVSAvoidnumber of spin coat processes

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent combines carbon nanotubes with nanoscopic particles (such as silica or polymer beads) to form a composite coating material. This composite approach allows the nanoscopic particles to act as spacers that control the spacing and density of nanotubes during the spin coating process, enabling precise control over nanotube volume density while achieving significant film thickness in a single coating step.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The nanoscopic particles serve as intermediary elements that mediate the spacing and distribution of carbon nanotubes within the coating. These particles are dispersed throughout the coating material and prevent nanotube aggregation, thereby controlling the three-dimensional network structure and volume density of the nanotube fabric layer during spin coating.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Length of stationary object

If multiple spin coat processes are used to achieve significant film thickness, then thick films can be formed, but the process becomes inefficient and costly

Engineering Contradiction:

Improvefilm thicknessVSAvoidprocess efficiency

Core Design Contradiction:

Length of stationary objectVSProductivity

Solution Approach 1:

The composite coating material containing nanoscopic particles enables the formation of thick, uniform films in a single spin coating process. The nanoscopic particles provide structural support and spacing that maintain film integrity at greater thicknesses, eliminating the need for multiple sequential coating steps and thereby improving process efficiency and reducing costs.

Inventive Principle:

Principle #40Composite materials

3Device complexity

If nanotube fabric layers are formed without nanoscopic particles, then the structure is simpler, but uniform nanotube density and thick film formation in a single process cannot be achieved

Engineering Contradiction:

Improvecoating material compositionVSAvoidnanotube density uniformity

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The addition of nanoscopic particles to the coating material creates a composite structure that, despite increased compositional complexity, delivers superior control over nanotube density uniformity. The nanoscopic particles act as spacers that prevent nanotube aggregation and ensure homogeneous distribution throughout the film, achieving uniform nanotube density that cannot be obtained with pure nanotube coatings.

Inventive Principle:

Principle #40Composite 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

This approach enables uniform nanotube density and thick film formation in a single spin coat process, reducing costs and improving performance in applications like nonvolatile memory cells and programmable logic devices by optimizing electrical switching characteristics.

Implementation Method 1

spin coating, allowing for controlled nanotube volume density and thick film formation in a single process

Methodology Applied

Scientific EffectSpin coating: Spin Coating

Implementation Method 2

using processes like solubilization, filtration, and pH adjustment to create a stable colloidal system

Methodology Applied

Scientific EffectSolubilization: Solvation

Implementation Method 3

using processes like solubilization, filtration, and pH adjustment to create a stable colloidal system

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS10181569B2Two-terminal switching devices comprising coated nanotube elements

Publication Date: 2019.01.15 ZEON CORP

AI summary

An improved switching material for forming a composite article over a substrate is disclosed. A first volume of nanotubes is combined with a second volume of nanoscopic particles in a predefined ration relative to the first volume of nanotubes to form a mixture. This mixture can then be deposited over a substrate as a relatively thick composite article via a spin coating process. The composite article may possess improved switching properties over that of a nanotube-only switching article. A method for forming substantially uniform nanoscopic particles of carbon, which contains one or more allotropes of carbon, is also disclosed.