Precision Sapphire Discharge Needle with Tapered Tip Sapphire Crystal Rod
A sapphire discharge needle is a precision discharge component manufactured from single-crystal sapphire (Al₂O₃). Its core characteristics stem from the physical and chemical properties of sapphire:
1. Crystal Structure
- Trigonal crystal system with tightly arranged atoms, providing ultra-high hardness (Mohs 9) and compressive strength (2.1 GPa).
2. Thermal Properties
- Melting point of 2050°C and thermal conductivity of 23–26 W/(m·K) (parallel to the c-axis), enabling stable operation across a wide temperature range (-40°C to 300°C).
3. Electrical Properties
- Dielectric constant of 9.4–11.58 and insulation strength ≥10 kV/mm, supporting high-voltage discharge (typical range: 8–12.5 kVpp).
Sapphire Discharge Needles Key Features and Advantages
1. Precision Machining Capability
- Tip Precision: Guided mode growth technology ensures tip curvature radius ≤5 μm and discharge point diameter ≤10 μm, sapphire discharge needles ideal for nano-scale electrostatic elimination.
- Surface Treatment: Sapphire discharge needles's ultra-precision grinding achieves surface roughness Ra ≤5 Å, minimizing arc diffusion during discharge.
2. Longevity and Reliability
- Abrasion Resistance: Sapphire’s hardness is 3× that of tungsten steel, sapphire discharge needles enabling 10⁶ discharge cycles (vs. 10⁴ for conventional tungsten needles).
- Chemical Inertness: Sapphire discharge needles resists dust adhesion, extending cleaning intervals to 30 days (vs. 7 days for standard materials).
3. Multi-Scenario Adaptability
- Voltage Range: Sapphire discharge needles supports pulse DC (DC) and AC modes with ±0.1 kV voltage regulation precision.
- Environmental Tolerance: Sapphire discharge needles operates stably in humidity 10–95% (non-condensing) and altitudes up to 5000 m.
4. Smart Integration
- Real-Time Monitoring: Integrated temperature sensors (±0.5°C accuracy) and current feedback systems enable automatic shutdown during anomalies.
- Remote Control: Adjustable parameters (frequency, voltage, duty cycle) via RS485 interface.
Sapphire Discharge Needles Core Applications and Technical Details
1. Semiconductor Manufacturing
- Wafer Electrostatic Elimination: Sapphire discharge needles installed on lithography machine wafer stages to neutralize ±5 kV static on silicon surfaces, improving yield by 3%.
- Equipment Protection: Sapphire discharge needles used in ion implanters to withstand 10¹⁵ ions/cm² high-energy particle bombardment.
2. Electronics Assembly and Packaging
- PCB Electrostatic Neutralization: Sapphire discharge needles neutralizes residual charge (≤50 V) on circuit boards in SMT lines, preventing component breakdown.
- Packaging Anti-Sticking: Eliminates static (surface resistance 10¹²–10¹³ Ω) on plastic films to prevent dust adhesion.
3. Medical Devices
- Surgical Instruments: Sapphire scalpels (tip curvature radius 20 μm) enable precise tissue cutting with minimal thermal damage (e.g., ophthalmic microsurgery).
- Endoscope Components: Withstand 134°C/30 min autoclave cycles for electrostatic shielding in gastrointestinal examinations.
4. New Energy and Automotive
- Battery Production: Eliminates static (charge density ≤1 μC/m²) on lithium battery electrodes to prevent short circuits.
- Charging Infrastructure: Deploys in high-voltage charging interfaces to avoid arcing (discharge current ≤10 mA).
5. Research and Defense
- Laser Systems: Sapphire discharge needles acts as window material for high-power lasers, enduring 10⁶ W/cm² optical thermal loads.
- Missile Radomes: Sapphire rods in guidance system optics withstand impacts ≥50 GPa.
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Sapphire Discharge Needles Q&A
1. Q: What is a sapphire discharge needle?
A: A sapphire discharge needle is a precision electrostatic elimination component made from single-crystal sapphire (Al₂O₃), used to neutralize static electricity in industrial and electronic applications.
2. Q: How to maintain a sapphire discharge needle?
A: Regularly clean the needle tip with alcohol to remove contaminants and inspect for wear, replacing it if discharge efficiency declines.
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