Single-Nozzle Multi-Layer Spray Coating With In-Situ Thickness Control
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Solution Overview
Problem
Existing spray coating technologies face challenges in automating the deposition of multiple 2D layers on a single stage, requiring multiple nozzles or manual intervention, leading to increased costs, reduced reproducibility, and lack of film thickness monitoring, which hinders the commercialization of multi-layer coatings.
Innovation Solution
An automated spray coating system with a single nozzle head and multiple feed design for sequential deposition of different layers, incorporating in-situ film thickness monitoring and annealing, and enabling autonomous fabrication in an inert atmosphere, eliminating the need for intermediate steps and manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple spray nozzles are used to deposit multiple 2D layers, then deposition coverage is improved, but device complexity and cost increase
Solution Approach 1:
The system segments the multi-layer deposition process into sequential single-nozzle operations. A single spray nozzle alternates between different precursor inks delivered through separate feed lines, achieving multi-layer deposition without requiring multiple physical nozzles. This segmentation of the material supply system enables complex multi-ink deposition while maintaining simple nozzle hardware.
Solution Approach 2:
The single spray nozzle is designed to perform multiple functions by alternating between different precursor inks. The nozzle serves as a universal deposition tool that can deposit various materials (e.g., perovskite, charge transport layers, electrode materials) sequentially, eliminating the need for dedicated nozzles for each layer type.
2Adaptability or versatility
If manual intervention is used for changing precursor ink, then flexibility is improved, but time consumption and lack of reproducibility increase
Solution Approach 1:
The system implements automated precursor ink switching through a computer-controlled valve system that automatically selects and switches between different feed lines based on the deposition sequence. The system self-manages the ink changing process without human intervention, maintaining flexibility while eliminating time loss and improving reproducibility through automated control.
Solution Approach 2:
The system incorporates automated control mechanisms that monitor the deposition process and trigger precursor switching at appropriate intervals. The computer-controlled system tracks the deposition sequence and automatically activates the corresponding feed line, ensuring precise timing and eliminating manual intervention delays.
3Device complexity
If film thickness monitoring is not implemented, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The system incorporates real-time film thickness monitoring using optical sensors that measure the thickness of deposited layers during the spray deposition process. The monitoring system provides feedback to the control system, which adjusts deposition parameters (such as spray duration, nozzle-to-substrate distance, or precursor flow rate) to maintain precise thickness control across all layers.
4Manufacturing precision
If multiple deposition stages are used for different layers, then layer quality is improved, but productivity and repeatability worsen
Solution Approach 1:
The system enables continuous multi-layer deposition by eliminating intermediate transfer steps between layers. The substrate remains in place while the single nozzle sequentially deposits different precursor inks without removing or repositioning the substrate. This continuous process maintains layer quality through controlled deposition while significantly improving productivity by avoiding repeated handling and transfer operations.
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 enhances deposition speed, accuracy, and repeatability by allowing multi-layer coating in a single run, reducing costs and improving the quality of deposited films through precise thickness control and in-situ annealing.
Implementation Method 1
The atomization of film deposition is generated in different ways, like cavitation of the precursor, droplet size, and high flow gases
Implementation Method 2
a liquid precursor is mechanically forced by a carrier gas towards the target surface
Implementation Method 3
the in-situ annealing provision is provided after the deposition of each layer
Data Source
AI summary
Automated multi-layer two-dimensional printing is provided via a plurality of supply tanks; a deposition tank; a plurality of pumps each comprising: a pipeline in fluid communication with one supply tank and the deposition tank on opposing ends; a bearing holder, including a plurality of rotatable bearings arranged at a shared angle to each other relative to an axis of rotation for the bearing holder; a housing wall, wherein at least a subset of the plurality of rotatable bearings compresses the pipeline against the housing wall; and a motor configured to rotate the bearing holder about the axis of rotation and push a fluid through the pipeline by moving the plurality of rotatable bearings about the axis of rotation to change where the rotatable bearings compress the pipeline against the housing wall; and a spray deposition nozzle in fluid communication with the deposition tank.