Oxide Shell Structures via Solvophobic Vapor Condensation
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Solution Overview
Problem
Despite significant efforts, there has been a lack of new findings in broadening the range of materials and substances for forming porous honeycomb structures via the breath figure approach, limiting novel architectures and key applications.
Innovation Solution
The method involves forming an oxide shell layer on a substrate with a solvophobic surface by exposing it to precursors in the vapor phase, where a first precursor condenses to form liquid droplets, and a thin oxide shell is formed at the air-liquid interface of these droplets, which are then removed to produce a substrate with oxide shells, using conditions that allow controlled dimensions and surface properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional breath figure approach is used to form porous honeycomb structures, then simple and fast structure formation is achieved, but lack of new findings limits material range and application novelty
Solution Approach 1:
The patent changes the fundamental parameters of the breath figure approach by using solvophobic surfaces instead of traditional hydrophobic surfaces, and by controlling sequential condensation of different precursors. This parameter change enables the formation of oxide shells with controlled thickness and composition, expanding the range of materials from conventional polymers to various oxides including silica, titania, and zirconia.
Solution Approach 2:
The patent segments the precursor condensation process into sequential steps where different precursors condense at different times on the solvophobic surface. This segmentation allows independent control of shell thickness and composition by controlling the condensation conditions for each precursor, enabling novel material compositions and structures.
2Manufacturing precision
If oxide shell layer is formed by reacting precursors at air-liquid interface, then controlled shell thickness and composition are achieved, but complex vapor phase reaction process is required
Solution Approach 1:
The patent employs self-service principles where the solvophobic surface automatically directs precursor condensation to specific locations, and the air-liquid interface automatically provides the reaction environment needed for oxide shell formation. The system uses its own components (solvophobic surface, vapor phase precursors, liquid condensate) to achieve controlled shell formation without requiring complex external control mechanisms.
Solution Approach 2:
The liquid condensate formed on the solvophobic surface acts as an intermediary medium that facilitates the reaction of vapor phase precursors. The liquid phase provides a convenient environment for precursor reactions while being easily removable afterward, leaving behind the desired oxide shell structure with controlled thickness and composition.
3Area of moving object
If liquid droplets are removed after oxide shell formation, then high specific surface area structures are produced, but additional removal step is required
Solution Approach 1:
The patent applies the discarding principle to the liquid droplet template, which is intentionally formed and then completely removed after serving its purpose of directing oxide shell formation. The liquid droplets are discarded through simple evaporation or washing, leaving behind the desired high surface area oxide shell structures. This temporary use and subsequent removal of the liquid template enables the creation of porous and high surface area 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 the production of substrates with high specific surfaces, low volumetric density, and high surface roughness, suitable for various applications including surface coatings, photonics, and optoelectronics, with the ability to control the size and density of oxide shells for specific purposes.
Implementation Method 1
condensing a first precursor of the set of precursors on the substrate to form a plurality of liquid droplets
Implementation Method 2
forming a thin oxide shell at an air-liquid interface of one or more of the liquid droplets by reacting the other precursors of the set of precursors at the air-liquid interface of the liquid droplets
Implementation Method 3
providing a substrate having a solvophobic surface
Data Source
AI summary
Embodiments of the present disclosure provide for substrates having an oxide shell layer (e.g., a silica shell layer), methods of making an oxide shell layer, and the like.