Antimicrobial Layer Material With Afterglow PE-CVD Transport Control
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Solution Overview
Problem
Existing antibacterial coatings struggle with optimizing biocide release, particularly at an early stage, to effectively pass stringent antibacterial tests according to standards like ASTM E 2149 and JIS Z 2801/ISO 22196.
Innovation Solution
An antimicrobial layer material comprising a particulate biocidal active ingredient layer topped with a plasma-polymeric transport control layer deposited using the afterglow PE-CVD method, which enhances biocide release properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional transport control layer is used, then the coating structure is simple, but the biocide release properties are insufficient particularly at an early stage
Solution Approach 1:
The patent applies parameter changes by modifying the deposition method parameters - specifically using afterglow PE-CVD with a substrate positioned at least 30 times the dark space zone distance from the plasma electrode. This parameter change in the deposition process creates a transport control layer with optimized porosity and morphology that enables improved biocide release properties while maintaining a relatively simple single-layer structure.
Solution Approach 2:
The transport control layer deposited by afterglow PE-CVD inherently develops a porous structure that facilitates biocide release. The porous nature of the plasma-polymeric layer allows controlled diffusion of biocidal agents from the underlying layer, providing the required release profile without adding complex multi-layer structures.
2Reliability
If the transport control layer thickness is increased, then the release control is improved, but the layer thickness becomes too large affecting early release
Solution Approach 1:
Rather than increasing thickness to improve release control, the patent changes the deposition parameters - specifically using afterglow PE-CVD with optimized substrate positioning (≥30 dark space zones distance). This parameter change creates a layer with superior release control properties at much thinner dimensions (5-320 nm), thereby avoiding the thickness problem while achieving the desired release control.
Solution Approach 2:
The porous structure inherent in afterglow PE-CVD deposited layers provides effective release control at reduced thickness. The porosity enables controlled biocide diffusion pathways, allowing the layer to function as an effective transport control barrier without requiring large thickness that would impede early release.
3Reliability
If standard PE-CVD method is used, then the deposition process is simple, but the release properties are not optimized
Solution Approach 1:
The patent modifies PE-CVD process parameters by implementing afterglow deposition with the substrate positioned at least 30 times the dark space zone distance from the plasma electrode. This parameter modification transforms the standard PE-CVD process into an afterglow PE-CVD process, creating layers with optimized release properties while maintaining the fundamental simplicity of vapor deposition methodology.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The antimicrobial layer material achieves a favorable release profile, ensuring effective antibacterial performance that meets or exceeds the standards for antibacterial coatings, with improved biocide release at an early stage.
Implementation Method 1
the transport control layer is depositable or has been deposited in an afterglow PE-CVD method
Implementation Method 2
In an afterglow method, the substrate is positioned in a parallel plate reactor for a PE-CVD method (plasma-enhanced chemical vapor deposition method)
Data Source
AI summary
The invention relates to an antimicrobial layer material comprising a layer with a particulate biocidal active ingredient and, on top of that, a layer as transport control layer, wherein the transport control layer is depositable or has been deposited in an afterglow PE-CVD method. The invention further relates to a substrate coated with such an antimicrobial layer material, to the use of a plasma-polymeric layer deposited in an afterglow PE-CVD method as transport control layer for a particulate biocidal active ingredient, and to a method of producing an antimicrobial layer material and to a method of producing a substrate comprising an antimicrobial layer material.