Abstract: This invention relates to methods whereby nanoparticle liquid suspensions are used in conventional thermal spray deposition for the fabrication of high-quality nanostructured coatings. Ultrasound is used for disintegration of the as-synthesized particle agglomerates, nanoparticle dispersion in liquid media, and liquid precursor atomization.

Abstract: A photocatalytic oxidation purification system includes an ultra violet light source and a filter that comprises a pleated wire mesh substrate with a nanophase metal oxide oxidation catalyst suspended on the substrate, wherein the catalyst is applied without an adhesive using an electromechanical plating process. As a fluid containing organic contaminants is directed through the filter in the presence of ultra violet light from the light source, the catalyst oxidizes and decomposes the organic contaminants into environmentally harmless components. Methods of making the purification system including preparing a solution of catalyst and applying the catalyst without adhesive binding material to the filter substrate electromagnetically.

Abstract: A diffusion barrier that has a low dielectric constant, k, yet resistant to oxygen and/or moisture permeability is provided. The diffusion barrier includes a dielectric stack having at least two or more dielectric films, each film having a dielectric constant of about 8 or less, wherein the dielectric stack comprises alternating films composed of a high-permeability material and a low-permeability material. A semiconductor structure including substrate having at least one wiring region and the inventive diffusion barrier formed on a surface of the substrate is also provided.

Abstract: The present invention relates to a method for carrying out a magnesium oxide based deposition on the dielectric surface of a glass plate of a display panel. The method includes the creation of a mist from a metalorganic compound of magnesium dissolved in a solvent, the conveying of the mist to the dielectric surface of the plate, the evaporation the solvent when approaching the dielectric surface of the plate which is taken to a temperature of about 380° to 430°, and the pyrolysis of the metalorganic compound leading to the magnesium oxide based deposit on the surface of the plate and the evaporation of the organic radical of the compound, this deposit being practically waterproof. The method is especially useful in the manufacture of plasma panels.

Abstract: A rod-like or thread-like material is subjected to a plasma treatment by passing the material coaxially through a plasma nozzle while generating plasma therein.

Abstract: A solder jet apparatus is disclosed The solder jet apparatus is a continuous mode solder jet that includes a blanking system and raster scan system. The use of the raster scan and blanking systems allows for a continuous stream of solder to be placed anywhere on the surface in any desired X-Y plane. This allows for greater accuracy as well as greater product throughput. Additionally, with the raster scan system, repairs to existing soldered surfaces can be quickly and easily performed using a map of the defects for directing the solder to the defects.

Abstract: Making a phosphor screen by forming a phosphor powder that incorporates strontium, is made up of particles having a long dimension of less than about 5 microns and having superior response time. Slurrying the phosphor powder with a suitable solvent, dispersant, plasticizer and binder. Coating a suitable substate with an infra red absorbing layer. Coating the phosphor containing slurry onto the infra red absorbing layer. Drying the thus produced screen.

Abstract: A system (100, 100′, 100″) and method for robotic manipulation of objects (130) is provided wherein particulates (110, 110′) are agitated by the transfer of energy thereto to establish patterned granular motion of the particulates (110, 110′). The patterned granular motion of the particulates (110, 110′) forms standing waves (112). The objects (130) align themselves with the standing waves (112) and thus are dynamically arranged in a configuration established by the location of the standing waves (112). The location of the standing waves (112) can be predetermined by controlling the waveform of the signals applied to the energy application system (140). The predetermined waveforms are supplied from the signal source (150, 154) to the energy application system (140).

Abstract: A method for producing a tantalum nitride layer on a substrate, comprising; directly injecting a liquid mixture of (R1R2N)3Ta(═NR3) and (R4R5N)3Ta[&eegr;2—R6N═C (R7)(R8)] into a dispersing zone followed by delivering the dispersed mixture into a reactor containing the substrate at elevated temperature and reacting the mixture with a source of nitrogen selected from the group consisting of ammonia, alkyl amines, N2H2, alkyl hydrazine, N2 and mixtures thereof, to produce the tantalum nitride layer on the substrate, where R1, R2, R3, R4, R5, R6, R7 and R8 are individually C1-6 alkyl, aryl or hydrogen.

Abstract: The amount of coating dispensed by a metering rod type applicator such as used on size press coater for applying coating onto the size press rolls can be reduced by vibrating the metering rod. Such vibration of the metering rod has been found to reduce the thickness of the film passing through the metering nip of the coating applicator for a given metering nip rod pressure.

Abstract: Improved assembly and methods for manufacturing a three-dimensional object are described. The assembly includes a crucible for holding molten metal, an orifice disposed in the bottom of the crucible through which a jet of molten metal can flow towards a movable substrate, and a mechanically oscillating member immersed in the molten metal for controlling the flow of molten metal through the orifice and for breaking the flow of molten metal into the sequence of molten metal drops. As the drops land on the movable substrate, a three-dimensional object is built up. Continuously variable diameter or controllable planar jets may be used as the orifices. In forming drops from the output of a planar jet, the jet is first broken up by the oscillating member into horizontal cylindrical ligaments and the ligaments are then broken up into drops by acoustic energy applied by audio loudspeakers adjacent the falling ligaments. The assembly and methods are useful in the fields of rapid prototyping and materials processing.

Abstract: This invention relates to methods whereby nanoparticle precursor solutions are used in conventional thermal spray deposition for the fabrication of high-quality nanostructured coatings. The method allows combining nanoparticle synthesis, melting, and quenching into a single operation.

Abstract: A method for manufacturing metal structures in which minute drops of a liquid metal are emitted from an acoustic device through an inert gas. The presence of the inert gas at the surface of the liquid metal prevent the formation of an oxide skin which would absorb acoustic energy and hinder droplet formation and emission. The droplets are then emitted towards a substrate, which may form as a carrier, where they may be used to form solder bumps, circuit traces, or accepted to form a three dimensional device.

Abstract: A method and apparatus for improved metal oxide chemical vapor deposition on a substrate surface where the application boundary layer is reduced and where the uniformity of the application boundary layer is greatly enhanced in a reactor. Primary and secondary sonic or other disturbance sources are incorporated for introducing disturbance into the interior chamber of the reactor, or an oscillating or vibrating chuck is incorporated within the interior chamber, to influence the boundary layer thickness and uniformity.

Abstract: An apparatus is used to turn liquids into vapors for use in chemical vapor deposition. It uses a high-frequency ultrasonic plate to break the liquid into tiny droplets and a gas-dynamic sorting tower to reprocess larger droplets into smaller ones before quickly vaporizing them. The method can vaporize liquids with high efficiency even if they have low vapor pressures and limited thermal stability. The vapor concentration can be set to a known and reproducible value by setting the pumping rate. The apparatus can rapidly start and stop the vapor flow. The pressure drop in the carrier gas is very small. Only a very small dead volume of liquid is contained in the apparatus at any given time, so little is wasted when the system is cleaned.

Abstract: A method for treating the surface of substantially each deagglomerated particle of an array of easily agglomerated particles by contacting deagglomerated particles with a plasma-activated gas species and modifying the surfaces of the deagglomerated particles to aid subsequent incorporation of the particles into a matrix composition; the module for deagglomerating and dispersing the particles into the plasma-activated gas; the apparatus that comprises the deagglomeration module (322) and a reaction chamber (20) in which the particles are treated with the plasma-activated gas; the method for deagglomerating particles that may reagglomerate after plasma treatment; and a color composition containing plasma-treated pigment particles.

Abstract: To produce a high quality thin film by effectively removing the particles from the emitted substance and the oxygen retained under a high vacuum during the production of the thin film by laser ablation, there is provided a process for producing a thin film on a substrate by laser ablation in a vacuum chamber in which a laser beam is irradiated to a target to cause emission of a substance from the target and allowing the emitted substance to deposit on the substrate to grow a thin film on the substrate by laser ablation, the process including irradiating an ion beam to at least one of the substrate and a plume of the emitted substance formed between the substrate and the target.

Abstract: Coating system and method that allows coatings to be formed from a wide variety of coatable compositions that are entirely free of any solvents or, alternatively, have relatively little solvent in minor amounts effective to help dissolve one or more components of such compositions. A fluid composition is atomized and contacted with a carrier gas. The contacting occurs under conditions such that vaporization of substantially all of the atomized fluid composition occurs so as to form a vapor having a condensation temperature. The vapor is caused to flow to the surface of the substrate. The surface is at a temperature below the condensation temperature of the vapor. Consequently, the vapor condenses onto the surface to form the coating.

Abstract: A method for manufacturing metal structures in which minute drops of a liquid metal are emitted from an acoustic device through an inert gas. The presence of the inert gas at the surface of the liquid metal prevent the formation of an oxide skin which would absorb acoustic energy and hinder droplet formation and emission. The droplets are then emitted towards a substrate, which may form as a carrier, where they may be used to form solder bumps, circuit traces, or accreted to form a three dimensional device.

Abstract: An improved method of coating an optical fiber is disclosed. A transducer is submerged in a container of liquid coating material and activated so that it causes the formation of a wave of coating material within the container. The optical fiber is then drawn through the container and through the wave, the wave counterbalancing the negative meniscus produced by drawing the fiber through the container. A curved housing also may be placed in the container and surrounding the transducer for controlling the size, amplitude, shape, or direction of the wave. A plurality of transducers also advantageously may be used.

Abstract: Repetitively pulsed plasma jets generated by a capillary arc discharge at high stagnation pressure (>15,000 psi) and high temperature (>10,000 K) are utilized to produce 0.1-10 .mu.m sized metal powders and decrease cost of production. The plasma jets impact and atomize melt materials to form the fine powders. The melt can originate from a conventional melt stream or from a pulsed arc between two electrodes. Gas streams used in conventional gas atomization are replaced with much higher momentum flux plasma jets. Delivering strong incident shocks aids in primary disintegration of the molten material. A series of short duration, high pressure plasma pulses fragment the molten material. The pulses introduce sharp velocity gradients in the molten material which disintegrates into fine particles. The plasma pulses have peak pressures of approximately one kilobar. The high pressures improve the efficiency of disintegration. High gas flow velocities and pressures are achieved without reduction in gas density.

Abstract: An improved method of coating an optical fiber is disclosed. A transducer is submerged in a container of liquid coating material and activated so that it causes the formation of a wave of coating material within the container. The optical fiber is then drawn through the container and through the wave, the wave counterbalancing the negative meniscus produced by drawing the fiber through the container. A curved housing also may be placed in the container and surrounding the transducer for controlling the size, amplitude, shape, or direction of the wave. A plurality of transducers also advantageously may be used.

Abstract: The present invention relates to new methods of impregnating plastic substrates with photochromic additives. By impregnating the plastic substrate in multiple impregnation steps under varying conditions, the concentration profile of two or more photochromic additive within the plastic substrate can be independently controlled. Methods are also provided for the distribution of a photochromic additive in a high boiling solvent and for increasing the glass transition temperature of a partially cured polymeric resin.

Abstract: The present invention provides an acoustic dispenser for propelling objects toward a substrate, together with methods of use of the dispenser. The acoustic dispenser uses a source of acoustic vibration and a membrane for the application of acoustic vibration wherein the objects are propelled from the membrane to a substrate. The acoustic dispenser and the methods of the invention can be used with numerous types of objects. In some embodiments, the objects are particles in a dry powder, which can include, for example, a pharmaceutically active ingredient. In other embodiments, the objects are beads, which preferably have an average diameter of about 100 to about 300 microns. Additionally, the acoustic dispenser can be used with more than one type of object, for example, two types of objects such as beads and dry powder.

Abstract: A precursor liquid comprising several metal 2-ethylhexanoates, such as stroritium tantalum and bismuth 2-ethylhexanoates, in a xylenes/methyl ethyl ketone solvent is prepared, a substrate is placed within a vacuum deposition chamber, the precursor liquid is misted, and the mist is flowed into the deposition chamber while maintaining the chamber at ambient temperature to deposit a layer of the precursor liquid on the substrate. The liquid is dried, baked, and annealed to form a thin film of a layered superlattice material, such as strontium bismuth tantalate, on the substrate. Then an integrated circuit is completed to include at least a potion of the layered superlattice material film in a component of the integrated circuit.

Abstract: A method for fabrication of polymer composite layers in a vacuum is disclosed. More specifically, the method of dissolving salts in a monomer solution, vacuum flash evaporating the solution, condensing the flash evaporated solution as a liquid film, and forming the condensed liquid film into a polymer composite layer on a substrate is disclosed.

Abstract: This invention discloses a decorative sheet having a hammer tone texture and the method used to obtain such hammer tone texture. A hammer tone composition is agitated, applied to a decorative sheet using a controlled means of delivery in a sufficient thickness, and then dried at a sufficient temperature and for a sufficient time to provide the hammer tone texture on the decorative sheet.

Abstract: A method and apparatus for coating the surface of a substrate suspends a coating material above the surface of the substrate and irradiates both the coating material and the underlying surface of the substrate. By irradiating both the coating material and the underlying surface of the substrate, a first portion of the coating material is melted to form an at least partially molten droplet of coating material. In addition, at least a second portion of the coating material is ablated to thereby create an ablation plume which propels the at least partially molten droplet of coating material toward the substrate. In addition, the portion of the substrate toward which the at least partially molten droplet of coating material is propelled is simultaneously heated, such that the at least partially molten droplet coating material adheres to the heated substrate, thereby coating the surface of the substrate.

Abstract: A method of depositing fluid using acoustic droplet ejectors onto a receptor until the desired layer is formed.

Abstract: This invention concerns a method for producing a magnetic recording medium by passing a magnetic coating material comprising a ferromagnetic powder and a binder resin through an ultrasonic treating device under the operating conditions of 10 to 200 kHz of frequency of oscillation and 10 to 100 .mu.

Abstract: The present invention is directed to an apparatus for manufacturing a free standing solid metal part. In the present invention metal droplets are produced from a free surface pool of molten metal is when an acoustic wave impacts an acoustic lens that is contiguous with the free standing pool of molten metal. The metal droplets are then charged and deflected toward a target. The build up of the metal droplets combine to form the free standing solid metal part.

Abstract: In supersonic molecular beam etching, the reactivity of the etchant gas and substrate surface is improved by creating etchant gas molecules with high internal energies through chemical reactions of precursor molecules, forming clusters of etchant gas molecules in a reaction chamber, expanding the etchant gas molecules and clusters of etchant gas molecules through a nozzle into a vacuum, and directing the molecules and clusters of molecules onto a substrate. Translational energy of the molecules and clusters of molecules can be improved by seeding with inert gas molecules. The process provides improved controllability, surface purity, etch selectivity and anisotropy. Etchant molecules may also be expanded directly (without reaction in a chamber) to produce clusters whose translational energy can be increased through expansion with a seeding gas.

Abstract: A method is provided for forming thin films, such as high temperature superconductors, on a surface of a substrate using pulsed microwaves to control substrate temperature. The method includes vaporizing a liquid source to form a series of vapor pulses, irradiating the vapor pulses and a makeup gas with pulsed microwaves, and exposing the surface of the substrate to the irradiated mixture to form a thin film on the surface. The microwaves may be pulsed to coincide with the arrival of the vapor pulses at the substrate, thus reducing the amount of material consumed and the amount of waste. Further, the plasma may be closely confined to the substrate with a dielectric waveguide to reduce the power required for irradiating the mixture and to prevent the formation of stray deposits on surfaces enclosing the substrate.

Abstract: An ultrasonically assisted coating method for applying a smooth layer of coating material on a surface of a moving web are disclosed. A coating material is applied onto one web surface. An ultrasonic energy generator excites the line of initial contact between the coating material and the web at a uniform ultrasonic intensity selected in combination with the properties of the coating material. The coated web has a thin, uniform crossweb thickness with low thickness variations.

Abstract: An atmospheric process for the production of a coating of film upon a nickel-containing substrate. In the first step of this process, an aerosol mist containing reactants necessary to form the coating is provided. Thereafter, the mist is subjected to radio-frequency radiation while in the plasma region. Thereafter, the vaporized mixture is then deposited onto a nickel substrate. In subsequent steps, one or more other layers of vaporized material may be deposited onto the coated substrate.

Abstract: This invention relates to a composite vapor deposition film composed of a plurality of elements and a method for manufacturing the same. A composite vapor deposition film is produced by having a composite of multi-component particles turned into a vapor to instantaneously evaporate the multi-component particles to an energy active vapor phase state. The composite vapor phase substance is solidified on a deposition substrate to form the vapor deposition film.

Abstract: An apparatus and method for uniformly coating a fiber or tow of fibers (10) with a powder at relatively high speed to produce a prepreg. The apparatus uses an elongated chamber (401) in a container (400) for confining the fiber which is coated by an aerosol of powder dispensed from a powder dispensing apparatus (500) in counter-current mode. A fiber tensioning apparatus (300) for the fiber maintains the proper tensioning of the fibers spread by a speaker (201) below the fibers on roller bars (203) so that the uniformly spread fibers are fed to the chamber (401). A heater apparatus (600) fuses the powder to the fiber and then is taken up on a spool (700).

Abstract: An atmospheric process for the production of a coating or film for electrochemical cells is disclosed. In the first step of this process, an aerosol mist containing reactants necessary to form the desired coating or film is provided. Thereafter, the mist is subjected to radio-frequency radiation while in the plasma region. Thereafter, the vaporized mixture is then deposited onto a substrate.

Abstract: In an apparatus for generating a fine dispersion of particles in a gas, a body (47) for containing the gas has an inlet (59a, 59b) and an outlet (60) for passage of the particles. Nozzles (55) are provided to direct a plurality of jets of gas through the body (47). The body (47) is maintained at an elevated temperature by a heating element (49).

Abstract: In accordance with this invention, there is provided an atmospheric process for the production of a ferritic coating or film. In the first step of this process, an aerosol mist containing reactants necessary to form the ferrite is provided. Thereafter, the mist is subjected to radio-frequency radiation while in the plasma region. Thereafter, the vaporized mixture is then deposited onto a substrate.

Abstract: A process for coating a superconductive film onto a substrate is provided. In the first step of this process, a solution of the reagents required to produce the superconductive material is subjected to ultrasonic sound waves to create an aerosol. Thereafter, the aerosol is contacted with plasma while being subjected to substantially atmospheric pressure and a radio frequency alternating current in excess of 100 kilohertz; a vapor is produced in this step. The vapor so produced is passed through an orifice and allowed to deposit onto a substrate, which is in contact with a substrate holder which is electrically grounded.