Pulse-Controlled Powder Transfer for Low-Temperature Direct Printing
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Solution Overview
Problem
Conventional methods for direct printing using aerosolized powder struggle to precisely control the amount and timing of aerosolized particles deposited on a substrate, especially at low temperatures, leading to difficulties in forming small-scale patterns without additional heat treatment.
Innovation Solution
An apparatus with an on-off valve system that intermittently separates the high-pressure and low-pressure sides to enhance the pressure difference, allowing for precise control of aerosolized powder supply and discharge through pulse control, enabling focused deposition and pattern formation without the need for masks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional aerosolized powder deposition methods are used, then powder can be deposited on substrate, but precise control of amount and timing of aerosolized particles is difficult
Solution Approach 1:
The patent employs periodic pulse control of the on-off valve to intermittently supply aerosolized powder to the substrate. By controlling the duration and frequency of pulse signals, precise amounts of powder can be deposited at specific timing intervals, enabling accurate pattern formation while simplifying the control mechanism through rhythmic on-off cycling rather than continuous adjustment.
Solution Approach 2:
The deposition process is segmented into discrete pulse cycles where the valve opens for a predetermined time to deposit powder, then closes to pause. This segmentation allows independent control of each pulse duration to match the required pattern dimensions, making precise control of powder amount and timing achievable through simple temporal division of the supply process.
2Speed
If high-pressure transfer gas is used to accelerate particles, then particles can be deposited at high speed, but control of transfer timing and aerosolized powder flow rate is difficult
Solution Approach 1:
The high-pressure transfer gas is supplied periodically through pulse control of the on-off valve rather than continuously. Each pulse duration is predetermined to match the required deposition timing, enabling high-speed particle acceleration during active phases while maintaining precise temporal control through the rhythmic on-off cycling of gas supply.
Solution Approach 2:
The system dynamically adjusts the timing and duration of high-pressure gas supply pulses to match the deposition requirements. The on-off valve responds in real-time to control signals, enabling flexible adaptation of transfer timing and aerosolized powder flow rate to the specific needs of pattern formation while maintaining high deposition speed during active phases.
3Productivity
If continuous powder supply is used, then deposition can be maintained, but precise control of small-scale pattern formation is difficult
Solution Approach 1:
Instead of continuous powder supply, the system uses periodic pulse control where the on-off valve opens for predetermined durations to deposit powder for specific pattern sections, then closes to pause. This enables precise control of small-scale patterns through short, controlled pulses while maintaining overall deposition efficiency through continuous cycling of pulse sequences that cover the entire pattern area.
Solution Approach 2:
The continuous deposition process is segmented into discrete pulse cycles, each corresponding to a specific portion of the pattern. By dividing the total deposition into many small, controlled pulses with predetermined durations, the system achieves precise small-scale pattern formation while maintaining high productivity through efficient sequencing of these segmented deposition events.
4Temperature
If low temperature processing is used, then additional heat treatment is avoided, but control of powder aerosolization and deposition is challenging
Solution Approach 1:
The system compensates for low temperature processing challenges by using periodic pulse control of the on-off valve to create controlled aerosolization events. Each pulse generates a temporary high-pressure condition that facilitates powder aerosolization and deposition, while the rhythmic cycling maintains process control without requiring continuous high temperature conditions.
Solution Approach 2:
The system changes the temporal parameters of powder supply through pulse control, using predetermined pulse durations and frequencies to optimize aerosolization and deposition at low temperatures. By adjusting the timing and duration parameters of pulse signals rather than relying on thermal energy, the system achieves effective powder control without additional heat treatment.
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
Enables precise and efficient direct printing of small-scale patterns on substrates at low temperatures using dry and solid particles, minimizing aerosolized powder supply and ensuring reliable pattern formation without additional heat treatment.
Implementation Method 1
an on-off valve system that intermittently separates the high-pressure and low-pressure sides to enhance the pressure difference, allowing for precise control of aerosolized powder supply and discharge
Implementation Method 2
aerosolizing powder through a momentary pulse type valve control, discharging a desired amount of powder through a nozzle, directly applying the powder to the surface of a work target
Data Source
AI summary
Disclosed herein are apparatus and method for transferring, focusing and purging powder for direct printing at low temperature. A filter is provided between an operation chamber housing in which a work target is disposed and a reservoir tank which contains powder to adjust the amount of particles transferred from the reservoir tank into the operation chamber housing. A pressure unit connected to the reservoir tank generates air pressure for applying powder to the work target. A purging unit connected to the reservoir tank generates pressure for returning powder that has remained in the operation chamber housing, the filter, etc. to the reservoir tank after work has been completed. The apparatus is configured such that a series of process of transferring powder to be applied to the surface of the work target and returning remnant powder to the reservoir tank can be rapidly and smoothly conducted.