Porous materials functionalized by vacuum deposition

A porous material and functional technology, applied in vacuum evaporation plating, metal material coating process, paper coating, etc., can solve the problem of aggravating pore blockage

Active Publication Date: 2006-06-21
亚利桑那西格玛实验室公司
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

Although polymers for vacuum deposition applications have been successfully used in the art to impart specific functional properties to non-porous, non-permeable substrates, historically no attempt has been made to functionalize porous materials because the vacuum deposition process has been Thought to exacerbate pore clogging problems

Method used

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  • Porous materials functionalized by vacuum deposition
  • Porous materials functionalized by vacuum deposition
  • Porous materials functionalized by vacuum deposition

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0040] Example 1 - Hydrophobic / oleophobic coating

[0041] A functionalized melt-blown polypropylene nonwoven fabric was coated with a hydrophobic / oleophobic fluorinated acrylate polymer to create a repellent surface. The monomer was flashed at about 100 mTorr. The fabric is pretreated in a plasma field and exposed to monomer vapor for condensation within one second while traveling at a speed of approximately 50 m / min. The condensed monomer layer is cured in-line by electron beam irradiation within 100 milliseconds. An approximately 0.1 μm thick polymer coating was produced from the run and was found to provide sufficient repellency to water and oil with a surface energy of approximately 27 dynes / cm. The functionalized fabric repels both water-based and oil-based fluids while substantially maintaining the original permeability of the fabric. The material of the coating exhibits high performance as an electrostatically charged filter medium. The same coating process with th...

example 2

[0045] Example 2 - Hydrophilic coating

[0046] Meltblown polypropylene nonwovens were coated (in a separate test) with films of hydrophilic acrylate polymers functionalized with hydroxyl, carboxyl, sulfate, amino, amido, and ether groups. The monomer was flashed at about 10 mTorr. The fabric is pretreated in a plasma field and exposed to monomer vapor for condensation within one second while traveling at a speed of approximately 30 m / min. The condensed monomer layer is cured in-line by electron beam irradiation within 150 milliseconds. Polymer coatings of about 0.1 [mu]m thick were produced from the runs, which were found to provide sufficient wettability to water in all cases with surface energies of about 70-72 dynes / cm. The functionalized fabric absorbs water while substantially maintaining the original permeability of the fabric. The cladding material exhibits high performance as a water-absorbing medium. The same layup process with the same hydrophilic acrylate monomer...

example 3

[0049] Example 3 - Hydrophobic / oleophobic pigmented coating

[0050] The same experiment as in Example 1 was repeated with 3-5% of an organic dye (such as disperse red) mixed in the fluorinated acrylate monomer. The coating base exhibited the same level of water and oil repellency, measured as approximately 6 and 5, respectively, in the DuPont(R) Teflon(R) repellency test with the color added to the coating. By monitoring the amount of organic dye or the thickness of the coating, the intensity of the color can be controlled.

[0051] Example 4 - Hydrophilic Pigmented Coating

[0052] The same experiment as in Example 2 was repeated with 3-5% of an organic dye (eg malachite green) mixed in a hydrophilic acrylate monomer. The coating base exhibited a pigmented surface with comparable high water absorption.

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Abstract

A porous substrate (12) is pretreated in a plasma field (20) and a functionalizing monomer is immediately flash-evaporated (22), deposited and cured (24) over the porous substrate in a vacuum-deposition chamber (10). By judiciously controlling the process so that the resulting polymer coating adheres to the surface of individual fibers in ultra-thin layers (approximately 0.02-3.O micrometers) that do not extend across the pores in the material, the porosity of the porous substrate (12) is essentially unaffected while the fibers and the final product acquire the desired functionality. The resulting polymer layer is also used to improve the adherence and durability of metallic and ceramic coatings.

Description

[0001] related application [0002] This invention is based on US Provisional Application Serial No. 60 / 465,719 filed April 25,2003. technical field [0003] The present invention generally relates to the functionalization of the surfaces of materials with the aim of improving their properties for specific applications. In particular, the present invention relates to a combined plasma treatment / vapor deposition process for functionalizing paper, separators, and other woven and nonwoven porous materials. Background technique [0004] The term "functionalization" and related terms are used in the art and this application to refer to the process of treating a material to alter its surface properties to meet the specific requirements of a particular application. For example, the surface energy of a material can be manipulated to render it particularly hydrophobic or hydrophilic, as may be desired for a particular use. As such, surface functionalization has become routine in th...

Claims

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Application Information

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IPC IPC(8): C23C16/00B05D3/00B05D3/14B05D7/24B32B3/26B32B9/00C23C8/02C23C8/20C23C8/80C23C28/00C23C30/00
CPCB05D1/60B05D1/62B05D3/0493B05D3/142B05D3/144B05D5/083B05D2201/00B05D2202/00B05D2203/00B05D2256/00C23C8/02C23C8/20C23C8/80C23C14/562C23C28/00C23C30/00D06M10/025D06M10/08D06M10/10D06M14/18D06M14/20D06M14/22D06M14/24D06M14/26D06M14/28D06M14/30D06M14/32D06M14/34D06M14/36D06M15/263D06M15/277D21H19/08D21H19/16D21H19/82B01D2325/48
Inventor 迈克尔·G·米哈埃安盖洛·扬利济斯
Owner 亚利桑那西格玛实验室公司
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