Oblong Flame Thermal Spraying for Large-Area Amorphous Films
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Solution Overview
Problem
Conventional devices face challenges in forming large-area amorphous films efficiently, as they often result in inhomogeneous film temperature and require repeated thermal spraying, which can lead to substrate overheating and poor film quality.
Innovation Solution
A device with an oblong flame cross-section and dual cooling systems using inert gas and mist, allowing for efficient rectification and cooling of the flame, enabling the formation of large-area amorphous films with controlled cooling rates and reduced oxide formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional thermal spraying device with a narrow flame (about 30 mm diameter) is used, then high quality amorphous film can be formed, but large-area film formation becomes inefficient requiring repeated reciprocating operations
Solution Approach 1:
The spraying system is divided into multiple independent spray nozzles arranged in an array, with each nozzle contributing to a specific portion of the overall flame structure. This segmentation allows the system to achieve a wide effective spraying width while maintaining the quality characteristics of individual narrow flames, thereby enabling efficient large-area film formation without repeated reciprocating operations
Solution Approach 2:
The invention transitions from a single-point spray approach to a distributed array of spray nozzles, effectively changing the spatial dimension of the flame structure. By arranging multiple nozzles in a specific pattern, the system creates an extended flame structure that covers large areas while maintaining homogeneous temperature distribution and amorphous film quality
2Productivity
If the flame width is increased to enable large-area thermal spraying, then productivity improves, but flame temperature becomes inhomogeneous affecting film quality
Solution Approach 1:
Each spray nozzle in the array maintains its own localized flame characteristics with homogeneous temperature distribution. The individual nozzles are positioned and configured to ensure that each contributes a uniform flame segment, and the overall wide flame is formed by the constructive combination of these homogeneous local flames rather than a single large inhomogeneous flame
Solution Approach 2:
The system employs dynamic control of the spray parameters for each nozzle in the array, adjusting fuel flow, oxidizer flow, and nozzle positioning to maintain optimal flame temperature homogeneity across the entire wide flame structure. This dynamic adjustment ensures that as the system operates over large areas, temperature uniformity is preserved throughout the flame zone
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
The device achieves homogeneous, high-quality large-area amorphous film formation with reduced substrate temperature variations and minimal oxide inclusion, suitable for various alloys including metallic glass.
Implementation Method 1
a flame including a particulate material is sprayed by a thermal spraying gun toward a substrate, while the flame melting the particulate material
Implementation Method 2
the particulate material and the flame are cooled by a cooling gas before reaching the substrate
Implementation Method 3
the particulate material and the flame are cooled by a cooling gas
Data Source
AI summary
PROBLEM: To provide a large device and a method which is advantageous for forming a large-area amorphous film.SOLUTION: A device of the invention sprays a flame including a particulate material with a spraying machine toward a substrate, melts the material with the flame, and cools the material and flame by cooling gas before they reach the substrate to form an amorphous film. The spraying machine has particulate material spraying ports and flame spraying ports such that the flame including the material has an oblong cross section. Inert gas spraying ports are successively placed on both sides across the ports of the material and flame. Mist spraying ports are successively placed on both sides across the ports for the material, flame and inert gas. A skirt is attached/detached depending on a combustion gas or a film width to restrain film width narrowing and increase of film thickness deviation.