Spray Pyrolysis Nano-Coating for High-Temperature Heating Stability
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Solution Overview
Problem
Low temperature conductive coatings are unstable at high temperatures, prone to cracking, and costly to manufacture due to the need for high vacuum vapor deposition, with cerium and lanthanum doping being difficult to distribute uniformly, leading to increased electrical resistance and reduced conductivity.
Innovation Solution
A multi-layer conductive coating of nano-thickness is applied using spray pyrolysis at controlled temperatures and pressures, with a multi-layer insulating coating to prevent substrate diffusion, and a temperature monitor and control system for efficient power regulation, reducing the need for high temperature annealing and minimizing rare earth element usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high vacuum vapor deposition is used to achieve uniform composition and structure, then manufacturing precision is improved, but manufacturing cost increases and device complexity increases
Solution Approach 1:
The patent changes the deposition method from high vacuum vapor deposition to spray pyrolysis, altering the process parameters to achieve uniform composition and structure at lower cost. The spray pyrolysis process uses controlled spray rates, substrate temperatures (650-750°C), and solution compositions to produce uniform nanometer-thick conductive layers without requiring expensive high vacuum equipment
Solution Approach 2:
The patent replaces expensive, complex high vacuum deposition equipment with simpler, more affordable spray pyrolysis apparatus. The spray pyrolysis method uses readily available materials and equipment to achieve the desired uniform conductive coating, eliminating the need for costly vacuum systems while maintaining manufacturing precision
2Reliability
If cerium and lanthanum are doped to increase stability, then reliability is improved, but manufacturing precision deteriorates due to difficulty in uniform distribution
Solution Approach 1:
The patent optimizes the spray pyrolysis parameters including spray rate, substrate temperature, and solution composition to ensure uniform distribution of cerium and lanthanum dopants. By controlling the spray rate and thermal field during deposition, the rare earth elements are uniformly incorporated into the tin oxide matrix, achieving both stability and uniformity
Solution Approach 2:
The patent uses the spray pyrolysis process as an intermediary method to distribute cerium and lanthanum uniformly. The liquid precursor solution acts as a carrier, allowing the rare earth elements to be evenly dispersed throughout the conductive coating during the spray deposition process, avoiding the non-uniform distribution problems of direct doping methods
3Manufacturing precision
If one hour annealing at high temperature is applied to create uniform and stabilized coating, then manufacturing precision is improved, but loss of time increases and harmful factors increase due to contaminant diffusion
Solution Approach 1:
The patent changes the annealing parameters by reducing both temperature and time compared to conventional methods. The spray pyrolysis process produces coatings that require shorter annealing at lower temperatures to achieve uniform stabilization, reducing contaminant diffusion while maintaining coating quality
Solution Approach 2:
The patent performs preliminary uniform distribution of dopants during the spray pyrolysis deposition process itself, before annealing. This preliminary action ensures that cerium and lanthanum are already uniformly distributed in the as-deposited coating, reducing the annealing time needed for stabilization and minimizing harmful contaminant diffusion
4Manufacturing precision
If molar percentages of cerium and lanthanum are increased to help distribution, then manufacturing precision is improved, but electrical resistance increases and conductivity decreases
Solution Approach 1:
The patent optimizes the dopant concentration parameters by using controlled, low levels of cerium and lanthanum in the spray pyrolysis solution. The spray process parameters are adjusted to ensure uniform distribution at these lower concentrations, achieving adequate stability without excessive resistance increase that would occur with higher dopant loading
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 solution achieves stable and efficient high-temperature heating with consistent resistance and conductivity, reducing energy loss and manufacturing costs, while maintaining performance up to 600°C and extending the lifespan of the heating element.
Implementation Method 1
The multi-layer conductive coating of nano-thickness may be produced by spray pyrolysis. The spray pyrolysis can be carried out at a temperature of about 650° C. to about 750° C.
Implementation Method 2
The heating element includes electrodes and a multi-layer conductive coating of nano-thickness disposed between the substrate and electrodes
Data Source
AI summary
A heating apparatus includes a heating element adapted to be disposed on a substrate. The heating element includes electrodes and a multi-layer conductive coating of nano-thickness disposed between the substrate and electrodes. The multi-layer conductive coating has a structure and composition which stabilize performance of the heating element at high temperatures. The multi-layer conductive coating may be produced by spray pyrolysis.