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Micro-particle entrainment from density mismatched liquid carrier system.

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This study investigates particle transfer in dip-coating mixtures, overcoming density mismatches using a polymer binder and stirring. Optimized methods enable controlled particle entrainment for novel manufacturing processes.

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Area of Science:

  • Materials Science
  • Chemical Engineering
  • Surface Science

Background:

  • Micro-scale inorganic particles (>1 µm) pose challenges in dip-coating due to negative buoyancy and density mismatch with liquid carrier systems (LCS).
  • Controlled particle delivery in dip-coating is crucial for manufacturing but hindered by density differences between particles and the liquid matrix.

Purpose of the Study:

  • To investigate the particle transfer mechanism in complex density-mismatching mixtures for dip-coating applications.
  • To optimize the liquid carrier system (LCS) and understand the influence of solid loading and binder concentration on particle entrainment.
  • To identify coating regimes and critical parameters for effective particle transfer and substrate coverage.

Main Methods:

  • Optimized an LCS using a polymer binder and evaporating solvent.
  • Dispersed inorganic particles in the LCS via stirring at the 'just suspending' speed.
  • Investigated the effects of solid loading and binder volume fraction on particle transfer at room temperature.
  • Analyzed two distinct coating regimes: heterogeneous coating and effective viscous regime.

Main Results:

  • Observed two coating regimes: heterogeneous (particle clusters) at low capillary numbers and effective viscous (full coverage) at higher capillary numbers.
  • Found that 'zero' particle entrainment was not observed, attributed to binder presence and hydrodynamic particle flow from stirring.
  • Determined critical film thicknesses for particle entrainment, which were smaller than previously reported values for similar binder concentrations.
  • Demonstrated that stirring energy neutralizes density mismatch effects, with transferred particle matrices aligning with modified LLD expressions.

Conclusions:

  • The study elucidates particle transfer mechanisms in density-mismatching dip-coating mixtures.
  • Stirring energy effectively neutralizes density mismatch, enabling controlled high-volume solid transfer.
  • Findings support the development of novel manufacturing processes for controlled particle deposition.