Uniform Insulative Layer Deposition via Dynamic Substrate Motion
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Solution Overview
Problem
Existing methods for forming porous insulative layers in hybrid materials result in non-uniform thickness due to random particle distribution, leading to cornrowing effects that degrade electrical performance by creating pathways for eddy currents.
Innovation Solution
Controlled substrate movement during combustion chemical vapor deposition (CCVD) processes, including translational, rotational, and tilting movements, to achieve uniform deposition of insulative layers, combined with multiple passes and cooling periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If combustion chemical vapor deposition is used to form porous insulative layers, then the manufacturing cost is reduced and performance is improved, but the insulative layer thickness becomes non-uniform with cornrowing effects
Solution Approach 1:
The substrate is made movable during the deposition process, transitioning from a static to a dynamic state. The substrate undergoes controlled translational, rotational, and/or tilting movements while receiving combustion products, which distributes the deposited material more uniformly across the substrate surface and eliminates the cornrowing effect caused by stationary deposition
Solution Approach 2:
The substrate movement is controlled and predetermined to occur during the deposition process. By pre-planning the movement pattern (translation, rotation, tilting) before deposition begins, the system ensures that all areas of the substrate receive equivalent exposure to the combustion products, achieving uniform thickness without requiring post-processing
2Quantity of substance
If multiple cornrowed layers are stacked to increase insulation, then the insulative thickness increases, but eddy current pathways are created through aligned thin regions
Solution Approach 1:
By making the substrate dynamic during deposition, each layer develops a uniform thickness profile without the cornrowing pattern. This prevents the formation of aligned thin regions when multiple layers are stacked, thereby eliminating preferential pathways for eddy currents and maintaining electrical performance across the hybrid material structure
3Device complexity
If the substrate remains stationary during deposition, then the process is simpler to control, but the particle distribution remains random and non-uniform
Solution Approach 1:
The substrate is transformed from a stationary to a dynamic element during deposition. Controlled movements (translation, rotation, tilting) are implemented to distribute particles uniformly. While this adds movement control mechanisms, the overall process remains manageable by coordinating substrate motion with the combustion product generation rate
Solution Approach 2:
The substrate undergoes periodic or continuous movement during the deposition process. By cycling through translation, rotation, and tilting motions, the system ensures that all substrate areas receive equivalent particle exposure over time, converting random instantaneous deposition into uniform cumulative deposition
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
Enhances the uniformity of insulative layers, reducing preferential current pathways and improving overall electrical performance by ensuring consistent thickness across the substrate surface.
Implementation Method 1
A common method for forming porous insulative layers is chemical combustion vapor deposition (CCVD). In this process, precursor chemicals are injected into a flame, where combustion reactions generate insulative particles that are then ejected and deposited onto a substrate.
Implementation Method 2
The present invention utilizes the movement of the substrate to generate a uniform layer of hybrid material. The substrate undergoes a combination of translational motion and independent dynamic adjustments before or as it receives the combustion product.
Implementation Method 3
In CCVD, combustion products are ejected from a combustion chamber and fall onto a substrate to become an insulative layer.
Data Source
AI summary
The present disclosure provides a method of producing a hybrid material comprising a first set of combustion chambers producing a combustion, a substrate at least once receiving a combustion product from the combustion chambers, and the substrate undergoing a combination of translational motion and independent dynamic adjustments before or as the substrate receives the combustion product. The translational movement may be generated by a conveyor system. The method may further comprise passing the substrate through a cooling environment after receiving the combustion product and passing the substrate through the combustion chamber multiple times to form a single insulation layer or multiple insulation layers. The independent dynamic adjustments create a more uniform insulation layer thickness and may be randomized. The combustion chambers may produce combustion at a variety of intensities, and the independent dynamic adjustments offset deposition irregularities caused by the variety of combustion intensities to improve uniformity.