Solid Particle Source Electron Beam Coating Throughput
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Solution Overview
Problem
Conventional methods for coating solid particles have low throughput and high costs, making them economically unviable for large-scale industrial manufacturing, and are complicated by the complex interplay of factors influencing electron-beam-based emission rates, leading to unpredictable and reproducible coating processes.
Innovation Solution
A method and system utilizing electron-beam-based emission of solid particles in a vacuum, combined with collective vibration to control particle density and resistance, allowing for a reproducible and temporally constant emission rate, thereby increasing throughput and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional coating methods (cathode sputtering, rebound vibration device, tumbling fluidized bed granulator) are used to coat solid particles, then coating can be achieved, but throughput is low and costs are high
Solution Approach 1:
The patent replaces conventional mechanical coating methods (cathode sputtering, rebound vibration devices, tumbling fluidized bed granulators) with an electron beam-based emission system. The electron beam gun emits electrons that charge solid particles electrostatically, causing them to repel and separate, enabling coating without mechanical contact or tumbling. This substitution dramatically increases throughput while reducing equipment complexity and operational costs.
Solution Approach 2:
The patent changes the fundamental parameter of particle charging from conventional mechanical or chemical methods to electrostatic charging via electron beam irradiation. By controlling electron beam parameters (current, energy, duration), the system achieves precise control over particle emission and coating deposition, enabling high-speed processing with improved reproducibility and reduced material waste.
2Reliability
If conventional coating methods are used, then coating can be achieved, but additional measures are needed to prevent particle adhesion and clustering
Solution Approach 1:
The patent replaces mechanical anti-adhesion measures with electrostatic repulsion. The electron beam charges particles positively, creating mutual repulsion that naturally prevents particle-particle adhesion and clustering during the coating process. This eliminates the need for additional mechanical devices or chemical agents to prevent clumping, simplifying the overall process while improving coating uniformity.
3Productivity
If electron beam-based emission is used, then throughput increases, but the complex interplay of factors makes emission rate unpredictable and non-reproducible
Solution Approach 1:
The patent implements feedback control by introducing a vibration source that couples vibration into the solid particle source. This vibration actively counteracts the complex interplay of factors (particle density, electron beam parameters, chamber conditions) that affect emission rate, maintaining temporal constancy and reproducibility. The vibration ensures consistent particle availability at the emission surface, enabling reliable high-throughput operation.
Solution Approach 2:
The patent applies mechanical vibration to the solid particle source as a control mechanism. The vibration source couples oscillatory motion into the particle bed, preventing particle agglomeration, maintaining uniform particle density at the emission surface, and ensuring consistent electron beam interaction. This mechanical intervention stabilizes the emission process, making high throughput reproducible despite the complex underlying physics.
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 approach enhances the throughput and reduces costs of coating solid particles, making the process more economically viable and reproducible, while maintaining control over emission rates and particle properties.
Implementation Method 1
introducing electrons into the solid particles in such a way that an electrostatic charging of the solid particles that is brought about by the electrons separates the solid particles from one another and accelerates them in a direction out of the container
Implementation Method 2
at least one electron source for introducing electrons into the solid particles
Implementation Method 3
a vibration source configured to couple a vibration into the solid particles arranged in the container for loosening the solid particles
Implementation Method 4
a material vapor source configured to vaporize a coating material into the coating region
Implementation Method 5
vaporize a coating material with a second main propagation direction into the coating region
Data Source
AI summary
The invention relates to various embodiments of a solid particle-source (100a, 100a) that can comprise: a container (104) which comprises an area for receiving solid particles; at least one electron source (106) for introducing electrons into the solid particles such that an electrostatic charge of the solid particles produced by the electrons separates them from each other and accelerates them in a direction out from the container (104); a vibration source (110) which is designed to introduce a vibration in the region in order to loosen the solid particles, the electronic source comprising an emission surface for emitting electrons into a vacuum emission region.