High-throughput powder synthesis system
First Claim
1. A collector for a powder synthesis system, comprising:
- a filter assembly including a feed zone, a collection zone, and a storage zone, and an elongated porous filter extending from the feed zone to the storage zone through the collection zone along a feed path, wherein the filter has a surface that is exposed when positioned in the collection zone;
a driver connected to the filter assembly that indexes the filter to positions along the feed path to progressively expose different areas of the surface of the filter in the collection zone for powder collection and advance the exposed areas of the surface of the filter toward the storage zone;
a film supply adjacent the storage zone that applies film to the surface of the filter in the storage zone to cover the previously exposed areas of the surface of the filter for retaining collected powder; and
an inert gas source in communication with the feed zone and the storage zone that provides a continuous flow of inert gas from the feed zone toward the collection zone and from the storage zone toward the collection zone thereby creating a barrier around the collection zone and an oxygen free environment around at least the storage zone.
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Abstract
The powder synthesis system integrates “on-the-fly” precursor formulation and delivery, control of carrier gas flow rate and temperatures of a multi-zone reactor (to control time-temperature history of the particles in the reactor), with rapid filtering/collection equipment into a powder synthesis process that is representative of actual manufacturing time-temperature conditions. A control system provides automatic operation and data acquisition, while requiring minimal operator involvement. The system includes a delivery stage, a production stage, and a collection stage. The collection stage uses a camera style filter apparatus to collect the powder with minimal loss and isolates each sample to prevent contamination.
31 Citations
25 Claims
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1. A collector for a powder synthesis system, comprising:
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a filter assembly including a feed zone, a collection zone, and a storage zone, and an elongated porous filter extending from the feed zone to the storage zone through the collection zone along a feed path, wherein the filter has a surface that is exposed when positioned in the collection zone;
a driver connected to the filter assembly that indexes the filter to positions along the feed path to progressively expose different areas of the surface of the filter in the collection zone for powder collection and advance the exposed areas of the surface of the filter toward the storage zone;
a film supply adjacent the storage zone that applies film to the surface of the filter in the storage zone to cover the previously exposed areas of the surface of the filter for retaining collected powder; and
an inert gas source in communication with the feed zone and the storage zone that provides a continuous flow of inert gas from the feed zone toward the collection zone and from the storage zone toward the collection zone thereby creating a barrier around the collection zone and an oxygen free environment around at least the storage zone. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A method of collecting samples in a powder synthesis system having a filter assembly with a feed zone, a collection zone and a storage zone, the method comprising:
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providing a flow of powder carried in a carrier gas;
providing an elongated porous filter that extends from the feed zone through the collection zone and to the storage zone;
exposing a portion of the filter to the flow of powder carried in the carrier gas in the collection zone to separate the powder from the carrier gas and accumulate powder on a surface of the exposed portion of the filter;
delivering a continuous flow of inert gas to the feed zone and the storage zone to create a barrier that inhibits powder from leaving the collection zone;
actuating the filter assembly to advance the exposed portion of the filter toward the storage zone and position an unexposed portion of the filter in the collection zone;
applying a film to cover the exposed portion of the filter and the accumulated powder in the storage zone; and
removing the exposed portions of the filter from the storage zone for analysis. - View Dependent Claims (15, 16, 17, 18)
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19. A method of synthesizing a high throughput of powder, comprising:
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providing an accessible database of operating conditions, including physical data relating to precursor solutions, precursor feed rates, elemental composition of target materials, processing temperatures, carrier gas flow rates, filter specifications, and other system parameters;
calculating variable control values based on the operating conditions;
determining a precursor formulation by selecting from individually stored chemical components;
mixing controlled amounts of the selected chemical components according to the calculated control values;
atomizing the mixture into droplets and entraining the droplets in a carrier gas;
processing the aerosol droplets by heating at a calculated processing temperature and converting the droplets into a fine powder entrained in the carrier gas;
cooling the carrier gas and powder to a calculated cooled temperature;
causing the carrier gas and powder to flow past a porous filter at a calculated rate to separate the powder from the carrier gas;
collecting and storing the powder on a surface of the porous filter; and
automatically monitoring and controlling the variable system parameters and automatically collecting data representative of actual operating conditions. - View Dependent Claims (20, 21, 22, 23, 24, 25)
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Specification