Antimicrobial air filters start with uniform nanoparticles. Making those particles consistently is hard with ordinary batch mixing. The spinning disc reactor solves that with a continuous, high-shear process. Here is how it works and why it matters.
How the SDR Synthesis Method Works
- Continuous reactant delivery: two water-based solutions, such as copper(II) chloride (CuCl2) and sodium hydroxide (NaOH), pump into the center of a rotating disc at the same time.
- High-shear thin-film reaction: centrifugal force and mechanical shear spread the liquids across the disc, where they react into uniform copper oxide nanoparticles about 9.1 ± 1.9 nm wide.
- Colloid ejection and collection: the reacted liquid travels outward, is ejected from the disc, then filtered, washed and oven-dried.
Precise Particle Size and Monodispersity
- The disc controls reaction time far better than batch co-precipitation.
- The result is uniform particles with a narrow size distribution around 10 nm.
- Uniform size is what makes a coating behave consistently.
Enhanced Residence Time Control
- Concave spinning disc designs hold the reactants along the rotating axis longer.
- That fixes the limited reaction-time control of flat-surface reactors.
High-Volume Scalability
- The continuous flow mechanism supports industrial-scale manufacturing.
- Production reaches up to 2 kg per hour per disc.
- That throughput is what moves the technology from lab to real-world filters.
Frequently Asked Questions
What is the spinning disc reactor?
A continuous-flow machine that spins two reactant liquids across a disc to form uniform nanoparticles, such as copper oxide, in seconds.
Why does particle uniformity matter?
Uniform particles behave consistently, so an antimicrobial coating performs the same across every filter.
Is this method used at commercial scale?
Yes. Its continuous flow scales to industrial volumes, up to 2 kg per hour per disc.
