Atmospheric Plasma Electrode Module for Large Substrate Coating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current plasma treatment systems for substrates, especially at atmospheric pressure, face limitations such as restricted processing volume, high costs, and the need for vacuum chambers, which hinder efficient treatment of large or high-volume substrates like textiles and plastics, and often result in destructive temperatures.
Innovation Solution
A modular plasma treatment system with removable electrodes and a fluid delivery system that operates at atmospheric pressure, allowing for the deposition of nanoparticle coatings and functional treatments in an open atmosphere, using a manifold to energize fluids and a bias means to attract them onto substrates, with a lacing system for guiding substrates and an exhaust system for fluid collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum-based plasma systems are used for substrate treatment, then surface modification quality is improved, but processing cost and complexity increase significantly
Solution Approach 1:
The patent changes the operating pressure parameter from vacuum to atmospheric pressure, enabling plasma treatment without vacuum chambers. This resolves the contradiction by maintaining effective plasma treatment (improving surface modification quality) while eliminating the complex vacuum infrastructure (reducing device complexity and cost).
Solution Approach 2:
The patent replaces the mechanical vacuum chamber system with an atmospheric pressure plasma jet system. This substitution eliminates the need for vacuum pumps, sealed chambers, and complex pressure control mechanisms, thereby reducing device complexity while maintaining treatment effectiveness.
2Device complexity
If atmospheric pressure plasma is used for treatment, then device complexity is reduced, but processing effectiveness decreases
Solution Approach 1:
The patent concentrates plasma energy into a focused jet that delivers high-density active species directly to the substrate surface. This local concentration of treatment effectiveness compensates for the lower overall plasma density at atmospheric pressure, maintaining reliable treatment results without requiring a vacuum chamber.
Solution Approach 2:
The patent employs a dynamic plasma jet system that can be moved or positioned to treat different areas of substrates. The jet's active species are delivered continuously and dynamically to the substrate surface, ensuring effective treatment at atmospheric pressure without the need for static vacuum chambers.
3Manufacturing precision
If plasma treatment is performed in a processing chamber, then treatment quality is maintained, but production rate decreases
Solution Approach 1:
The patent divides the treatment process into a portable plasma jet module that can treat substrates in a continuous or semi-continuous manner. This segmentation allows treatment to occur without loading/unloading large vacuum chambers, thereby maintaining treatment quality while significantly improving production rate through faster substrate throughput.
Solution Approach 2:
The plasma jet system is pre-positioned and ready to treat substrates immediately upon contact or close proximity. This preliminary preparation eliminates the time required for vacuum chamber pumping and pressure equalization, thereby maintaining treatment quality while accelerating the production rate through reduced cycle times.
4Productivity
If high power plasma is used for treatment, then processing speed is improved, but substrate damage from high temperature increases
Solution Approach 1:
The plasma jet operates in periodic or pulsed modes, delivering high-power treatment in short bursts followed by cooling intervals. This periodic action allows rapid processing (improving productivity) while preventing excessive heat accumulation that would cause substrate thermal damage.
Solution Approach 2:
The plasma jet rapidly passes over or through the substrate, delivering the required treatment in a very short time. This rushing through approach improves processing speed while minimizing the total thermal energy transferred to the substrate, thereby reducing thermal damage risk.
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
Enables efficient, cost-effective treatment of large substrates with improved processing speeds and the ability to apply functional coatings, while maintaining control over internal pressures and fluid management, reducing the risk of substrate damage from high temperatures.
Implementation Method 1
The use of ionized gases, which may be plasma, for treating, modifying and etching of material surfaces is well established within the field of fabrics
Implementation Method 2
a plasma is generated by the passage of gas through the two or more screen electrodes
Implementation Method 3
a bias means which may attract the fluids energised by the electrodes
Implementation Method 4
the electrodes are adapted to energise the fluid delivered from the manifold before being deposited onto the article
Data Source
AI summary
A system for treating an article. The system comprises a segment adapted to contain a local atmosphere and an internal pressure which is within the range of 90 kPa to 110 kPa. The segment comprising a module. The module comprising a pair of electrodes and a manifold for delivering a fluid to the pair of electrodes, wherein the electrodes are adapted to energise the fluid delivered from the manifold before being deposited onto the article.