Particle Collector Flow Sampler for In-Line Contamination Characterization
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Solution Overview
Problem
Existing methods for detecting and assessing contamination in manufacturing environments, such as clean rooms for hard disc drive production, face challenges in identifying the type of contamination in-line and non-intrusively, particularly in effectively collecting and characterizing particulates from gas flows.
Innovation Solution
The implementation of a flow direction structure with a flow sampler and particle collector that directs particulate-laden gas along a flow path, sampling a portion at reduced velocity to adhere particulates to a collecting surface, allowing for in-line, non-destructive collection and characterization of contaminants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a flow sampler is used to sample particulate-laden gas at reduced velocity, then particle concentration on the collecting surface is improved, but the device complexity increases
Solution Approach 1:
The apparatus is divided into distinct functional segments: a flow direction structure with interior sidewalls, a flow sampler positioned within the flow path, and a particle collector with a collecting surface. This segmentation allows each component to perform its specific function independently, achieving precise particle concentration measurement while maintaining manageable device complexity through modular design.
Solution Approach 2:
The flow sampler acts as an intermediary component between the incoming particulate-laden gas and the particle collector. It samples a portion of the gas flow at reduced velocity and directs it to the collecting surface, mediating the transition from high-velocity industrial gas flow to conditions suitable for accurate particle deposition and measurement.
2Manufacturing precision
If the flow velocity is reduced for sampling, then particle adhesion to the collecting surface is improved, but the productivity of contamination assessment decreases
Solution Approach 1:
The flow sampler extracts only a portion of the total particulate-laden gas flow for sampling and analysis, while the remaining flow continues through the system. This partial action approach allows sufficient particle collection for accurate assessment without requiring the entire gas flow to be slowed down, thereby maintaining overall system productivity while achieving the needed particle adhesion for the sampled portion.
3Measurement precision
If in-line particle collection is implemented, then contamination characterization accuracy is improved, but the ease of operation decreases
Solution Approach 1:
The apparatus is designed to operate autonomously within the existing gas flow path. The flow direction structure, flow sampler, and particle collector work together automatically to capture, concentrate, and deposit particles without requiring external intervention or complex operational procedures. The system serves itself by utilizing the existing gas flow dynamics to achieve accurate contamination characterization.
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 accurate characterization of particulates, achieving high trap rates for particles of various sizes, particularly 98.9% for particles greater than 0.5 microns, and facilitates real-time monitoring and analysis of contamination levels, enhancing manufacturing quality control.
Implementation Method 1
The flow direction structure has interior sidewalls configured and arranged to direct the flow of particulate-laden gas along a flow path
Implementation Method 2
The flow sampler is configured and arranged with the flow direction structure to sample a portion of the particulate-laden gas at a reduced velocity while allowing another portion of the particulate-laden gas to exhaust around the flow sampler
Implementation Method 3
The particle collector has a collecting surface, with the flow sampler being configured and arranged with the particle collector to direct the sampled portion of the particulate-laden gas to the collecting surface and to adhere particulates from the particulate-laden gas to the collecting surface
Data Source
AI summary
Aspects of the disclosure are directed to apparatuses and methods involving particulate sampling. As may be consistent with one or more embodiments, an apparatus includes a flow direction structure, a flow sampler and a particle collector having a collecting surface. The flow direction structure has interior sidewalls that direct the flow of particulate-laden gas along a flow path. The flow sampler is located in the flow path within the interior sidewalls, and operates with the flow direction structure to sample a portion of the particulate-laden gas at a reduced velocity, while allowing another portion of the particulate-laden gas to exhaust around the flow sampler. The flow sampler operates with the particle collector to direct the sampled portion of the particulate-laden gas to the collecting surface, and to adhere particulates from the particulate-laden gas to the collecting surface.