Electric field-assisted control of crystallization and particle morphology during evaporation

An additive-free manufacturing technology that uses externally applied electric fields to delay crystallization, control particle morphology, and produce denser, more uniform materials during evaporation-based processing.

BACKGROUND:

Industrial manufacturing processes including battery material production, spray pyrolysis, pharmaceutical particle synthesis, inkjet printing, and solution-based electronics fabrication depend on evaporation of liquids containing dissolved salts or functional precursors. During rapid evaporation, dissolved materials accumulate near the liquid surface, often triggering premature crystallization that produces hollow, porous, or non-uniform particles with reduced density, mechanical strength, conductivity, and long-term stability. Existing approaches typically rely on chemical additives, surfactants, solvent engineering, or extensive formulation optimization, increasing manufacturing complexity, contamination risk, and production costs.

TECHNOLOGY OVERVIEW:

This University at Buffalo technology actively controls crystallization during evaporation by applying a controlled external electric field across evaporating electrolyte droplets, aerosols, sprays, or thin liquid films. The applied field polarizes the solution and generates electric double layers at liquid interfaces, redistributing dissolved ions away from the bulk solution and delaying supersaturation until later in the evaporation process. As a result, crystallization occurs at a smaller droplet volume, producing denser particles with reduced hollow-shell formation and improved microstructural uniformity.

ADVANTAGES:

The additive-free process:

• Simplifies manufacturing and reduces contamination risk
• Increases crystal compactness from a volumetric fill fraction of ~0.60 to >0.90 (roughly a 50% improvement) while suppressing hollow particle formation
• Reduces crystal radius by up to ~25% under rapid drying conditions using only an applied electric field
• Is compatible with existing equipment

APPLICATIONS:

Battery material manufacturing, pharmaceutical particle synthesis, spray pyrolysis, inkjet printing, solution-based electronics fabrication, ceramic and catalyst particle production, specialty chemical manufacturing, aerosol processing, thin-film deposition, advanced materials manufacturing.

INTELLECTUAL PROPERTY SUMMARY: Patent pending.

STAGE OF DEVELOPMENT: TRL 7

LICENSING STATUS: Available for licensing or collaboration.