Particle Deposition Nozzle Geometry for Nanomaterial Coatings
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Solution Overview
Problem
The development of scalable and precise nanomaterial-based coatings for various industries has been unsuccessful due to challenges in achieving uniform deposition and controlling the porosity and thickness of film coatings.
Innovation Solution
A particle deposition system that includes a particle source providing nanomaterials at a controlled rate, coupled with a gas distribution system and a nozzle with adjustable geometry, allowing for precise control of impact velocity and porosity by manipulating nozzle geometry, substrate separation, pressure drop, and chamber pressures, enabling the deposition of films with varying porosity and thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional deposition methods are used to form nanomaterial coatings, then coatings can be formed in a laboratory setting, but scalable and precise deposition with uniform film properties cannot be achieved
Solution Approach 1:
The patent employs a gas distribution system with nozzles that deliver nanomaterials through controlled gas flow. The nozzle geometry (slit-shaped with specific length-to-width ratio) and gas pressure control enable precise delivery and uniform distribution of nanomaterials across the substrate surface, achieving both laboratory-quality uniformity and scalable production capability
Solution Approach 2:
The system controls multiple parameters including nozzle geometry (length, width, shape), gas pressure, substrate separation distance, and nanomaterial delivery rate. By optimizing and controlling these parameters simultaneously, the system achieves uniform film deposition with precise control over film properties while maintaining scalability for industrial production
2Manufacturing precision
If deposition parameters are not controlled, then deposition process is simpler, but porosity and thickness of film coatings cannot be controlled
Solution Approach 1:
The system incorporates adjustable and movable components including nozzles with variable geometry, adjustable substrate separation distances, and controllable gas pressure systems. These dynamic elements allow real-time adjustment of deposition parameters to precisely control film porosity (27%-95%) and thickness (5 nm-1 mm) while maintaining a relatively simple overall system architecture
Solution Approach 2:
The gas distribution system with configurable nozzles serves multiple functions: delivering nanomaterials, controlling flow distribution, adjusting film porosity, and regulating deposition rate. This multi-functionality reduces the need for separate complex control systems while achieving precise film property control
3Manufacturing precision
If nozzle geometry is fixed, then device complexity is reduced, but impact velocity and porosity cannot be precisely controlled
Solution Approach 1:
The nozzle design features adjustable geometry including variable slit width and configurable opening dimensions. The nozzle can be positioned at adjustable angles and distances from the substrate. These dynamic geometric adjustments enable precise control of nanomaterial impact velocity and resulting film porosity without requiring an overly complex nozzle structure
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 system achieves highly uniform and customizable nanomaterial coatings with porosity ranging from 27% to 95% and thickness from 5 nm to 1 mm, allowing for precise control of film properties, enabling the formation of both dense and porous films as needed.
Implementation Method 1
The nozzle can have a long narrow opening that accelerates the nanomaterial aerosol onto the substrate
Implementation Method 2
A particle deposition system in accordance with the present disclosure can include a particle source providing a nanomaterial at a controlled rate and a gas distribution system coupled with the particle source
Implementation Method 3
nanomaterial based coatings can be widely formed in a laboratory setting through deposition
Data Source
AI summary
A particle deposition system can have a particle source providing a nanomaterial at a controlled rate and a gas distribution system coupled with the particle source and operable to receive the nanomaterial aerosol. A high pressure chamber can be coupled with the gas distribution system, and a nozzle can be disposed between the high pressure chamber and a low pressure chamber. The nozzle can have a nozzle opening allowing fluidic communication of a nanomaterial aerosol between the high pressure chamber and the low pressure chamber and the opening can have a length exceeding a width.