Silicon-Based Composite Preparation Apparatus with Adjustable Inclination
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Solution Overview
Problem
Existing methods for preparing silicon-based composites face challenges such as high safety risks, high production costs, and low efficiency due to the use of hazardous silane precursors and complex chemical vapor deposition processes.
Innovation Solution
A composite preparation apparatus and method that includes a reactor with adjustable inclination, a heating module for maintaining target temperatures, and a collection system for separating and collecting the composite product, using solid and gas raw materials to produce silicon-based composites efficiently and safely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chemical vapor deposition (CVD) with silane precursor is used to prepare silicon-based composites, then the composite can be produced, but safety risks increase and production costs rise
Solution Approach 1:
The patent extracts and removes the hazardous silane precursor from the preparation process. Instead of using silane, the invention employs a solid-liquid reaction system where silicon source materials react with metal organic compounds in the presence of water, eliminating the need for dangerous gaseous precursors while maintaining the ability to produce silicon-based composites
Solution Approach 2:
The patent introduces water as an intermediary substance that enables the reaction between silicon source materials and metal organic compounds. This intermediary approach allows the reaction to proceed without requiring hazardous silane, using water instead as the activating agent for composite formation
2Productivity
If CVD process with multiple steps is used, then silicon-based composites can be prepared, but production efficiency decreases and operating costs increase
Solution Approach 1:
The patent merges multiple separate process steps into a single integrated reaction system. The solid-liquid reaction occurs in one continuous process where silicon source materials, metal organic compounds, and water are combined and reacted simultaneously, eliminating the need for multiple sequential CVD steps and thereby improving production efficiency while reducing operational complexity
Solution Approach 2:
The patent establishes a continuous reaction process where the solid-liquid reaction proceeds without interruption. The system maintains continuous mixing and reaction conditions, allowing for sustained composite production without the start-stop nature of traditional multi-step CVD processes, thereby enhancing productivity
3Ease of manufacture
If silane is used as precursor for composite preparation, then the reaction can proceed, but production costs increase
Solution Approach 1:
The patent replaces expensive silane precursor with cheaper, readily available materials including silicon source materials, metal organic compounds, and water. These inexpensive substitutes eliminate the high cost associated with silane while still enabling effective composite preparation through the solid-liquid reaction mechanism
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 apparatus and method enable the safe, efficient, and cost-effective production of high-performance silicon-based composites by controlling reaction conditions and reducing the complexity of the process, making it suitable for large-scale production.
Implementation Method 1
the heating module is configured to heat the main reaction zone and the post-processing reaction zone to target reaction temperatures, and maintain the temperatures constant
Implementation Method 2
the vacuum pump is configured to regulate the internal pressure of the reactor, and repeating the above operations to remove oxygen completely
Implementation Method 3
The collection device is configured to separate and collect the product from the gas-solid mixture
Implementation Method 4
the filter is configured to capture powders in the exhaust
Data Source
AI summary
A method and apparatus for preparing a composite, in which the angle between the apparatus base and the apparatus body is adjusted by the elevator device, the solid raw material is loaded into the reactor by the solid feeding device, the main reaction gas, the auxiliary gas and the carrier gas are introduced from the front gas intake unit into the main reaction zone at a preset ratio, followed by the active material deposited on solid particles, the post-processing reaction gas is introduced from the middle gas intake unit to the post-processing reaction zone to form a functional layer on the active material, the prepared composite powder is separated and collected from the gas-solid mixture in the collection device. The exhaust gas is released from the exhaust manifold into an exhaust gas treatment system after minority powder filtered by the filter.