Composite Filter Medium Moisture Removal for Plasma Coating Adhesion
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Solution Overview
Problem
Existing composite filter media face issues with incomplete polymerization and reduced water and oil repellency due to pressure variations in the plasma treatment chamber, caused by moisture release from the materials, leading to inadequate adhesion and chemical-physical properties of the coating.
Innovation Solution
A method involving a preliminary degassing step to remove moisture from the material before plasma treatment, followed by a reactivation plasma treatment to create nanometric roughness, ensuring complete polymerization and strong adhesion of the coating on the nanofibers and base fabric.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plasma treatment is applied to form coating on base fabric and nanofibers, then water and oil repellency is improved, but pressure increase in vacuum chamber causes incomplete polymerization and reduces coating adhesion
Solution Approach 1:
The patent applies a preliminary plasma treatment before the coating deposition step to remove moisture from the base fabric and nanofibers. This preliminary action prevents pressure increase during subsequent coating formation, ensuring complete polymerization and maintaining coating adhesion while achieving the desired water and oil repellency.
2Reliability
If plasma treatment is applied to form coating on base fabric and nanofibers, then water and oil repellency is improved, but coating adhesion to substrate is insufficient
Solution Approach 1:
The patent applies a preliminary plasma treatment before the coating deposition step to remove moisture from the base fabric and nanofibers. This preliminary action prevents pressure increase during subsequent coating formation, ensuring complete polymerization and maintaining coating adhesion while achieving the desired water and oil repellency.
3Productivity
If material with high moisture content is placed in vacuum chamber for plasma treatment, then industrial production of large diameter rolls is enabled, but pressure increase contaminates coating plasma feeding gas
Solution Approach 1:
The patent applies a preliminary plasma treatment before the coating deposition step to remove moisture from the base fabric and nanofibers. This preliminary action prevents pressure increase during subsequent coating formation, eliminating plasma gas contamination while maintaining the ability to process large diameter rolls in industrial production.
Solution Approach 2:
The patent divides the plasma treatment process into two separate steps: a preliminary plasma treatment step for moisture removal, and a subsequent coating deposition step. This segmentation allows each step to be optimized independently, preventing moisture-related pressure issues during coating formation while maintaining industrial production capability.
4Object-generated harmful factors
If pressure in vacuum chamber increases during plasma treatment, then moisture release from material is accommodated, but polymerization conditions change and coating performance deteriorates
Solution Approach 1:
The patent applies a preliminary plasma treatment before the coating deposition step to remove moisture from the base fabric and nanofibers. This preliminary action prevents pressure increase during subsequent coating formation, ensuring complete polymerization and maintaining coating performance while still accommodating moisture release in the initial step.
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 solution results in a composite filter medium with enhanced water and oil repellency, maintaining high air permeability and effective protection against liquid infiltration, while being easier to clean and maintaining acoustic impedance.
Implementation Method 1
a plasma coating is applied to the base fabric and the nanofibers... the monomer, injected into the plasma system chamber, polymerizes on the surface of the base fabric and the nanofibers
Implementation Method 2
the nanofiber layer is deposited on the base fabric by means of an electrospinning process
Implementation Method 3
a reactivation plasma treatment to create nanometric roughness
Data Source
AI summary
A method for preparing a composite filter medium (1), comprising a step of forming a first filter medium (8) through deposition of nanofibers (4) on a base fabric (2) through an electrospinning process and a step of covering said filter medium (1) by plasma deposition of a coating (7) on said first filter medium (8) in a vacuum chamber (9). According to the invention, after the electrospinning process and before the plasma deposition of the coating (7), a degassing step of the base fabric (2) and of the nanofibers (4) forming the aforementioned first filter medium (8) is provided inside the same chamber (9). With respect to the known filter media, that of the invention offers the advantage of maintaining the desired level of water and oil repellency, due to the formation of a completely polymerized coating strongly adhering to the surface of the base fabric and of the nanofibers.