Composite Filter Medium Plasma Treatment Adhesion
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Solution Overview
Problem
Existing composite filter media face challenges in maintaining effective repellency against water and oils while ensuring secure adhesion to PSA layers, leading to potential leaks due to poor adherence.
Innovation Solution
A composite filter medium is developed with a thin, highly hydrophobic and oleophobic coating applied via electrospinning and plasma treatment, followed by an additional plasma treatment step without polymer-containing gases to enhance adhesion to PSA layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a low surface energy coating is applied to ensure water and oil repellency, then liquid infiltration resistance is improved, but adhesion to PSA layers deteriorates
Solution Approach 1:
The patent applies a plasma treatment step before applying the low surface energy coating to introduce polar groups and increase surface energy. This preliminary action creates a dual-layer surface structure where the inner plasma-treated layer provides adhesion to PSA while the outer hydrophobic/oleophobic coating provides liquid repellency, thus resolving the contradiction between liquid resistance and adhesion strength
Solution Approach 2:
The patent creates different surface properties at different locations of the filter medium. The plasma treatment modifies the bulk surface to be adhesive, while the low surface energy coating is applied selectively to the outer surface to provide liquid repellency. This local differentiation allows the filter medium to simultaneously achieve both strong PSA adhesion and effective liquid infiltration resistance
2Strength
If a regular base fabric is used as substrate, then structural support is provided, but air permeability and acoustic impedance performance deteriorate
Solution Approach 1:
The patent creates a composite structure combining a regular base fabric with an electrospun nanofiber layer. The base fabric provides mechanical strength and structural support, while the nanofiber layer with controlled porosity and surface properties enhances air permeability and optimizes acoustic impedance. This composite material approach allows simultaneous achievement of structural integrity and acoustic performance
Solution Approach 2:
The patent employs a nanofiber layer with controlled porosity deposited on the base fabric. The porous structure of the nanofibers allows high air flow through the filter medium while maintaining structural support from the base fabric. The pore size and distribution are optimized to balance mechanical strength with acoustic permeability requirements
3Object-affected harmful factors
If nanofiber layer is deposited on base fabric by electrospinning, then particle filtration is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses the base fabric as an intermediary substrate to support the nanofiber layer during electrospinning and subsequent processing. This intermediary structure provides a stable platform for nanofiber deposition, simplifies handling of the delicate nanofiber mat, and facilitates integrated processing of the composite structure in a single manufacturing line, thereby reducing overall manufacturing complexity despite the advanced filtration capability
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 maintains high repellency against water and oils while ensuring strong adhesion to PSA layers, preventing leaks and facilitating easier assembly and cleaning.
Implementation Method 1
a layer of nanofibers (4) deposited on the base fabric (2) by means of an electrospinning process
Implementation Method 2
a plasma coating is applied to the base fabric (2) and the nanofibers (4)
Implementation Method 3
the repellency to water and oily liquids represents an obstacle to effective adhesion
Implementation Method 4
repellency to water and oily liquids
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
A method for preparing a composite filter medium (1), which involves a step of forming a first filter medium (8) by depositing nanofibers (4) on a base fabric (2) by means of an electrospinning process, a subsequent step of forming said filter medium (1) through plasma deposition of a coating (7) on said first filter medium (8) and a step of forming irregularities on the surface of said coating (7), through plasma treatment of the filter medium (1) obtained in the previous plasma deposition step. With respect to the known filter media, that of the invention offers the advantage of maintaining the desired level of water and oil repellency, without interfering with the secure adhesion of the filter medium to the body on which is located the opening to be protected against liquid infiltration.