Halogen-Free Plasma Coating for Hydro- and Oleophobic Fabrics

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Solution Overview

Problem

Existing methods fail to produce fabrics with effective hydro- and oleophobic properties without using per- and polyfluorinated substances (PFAS), which are environmentally persistent and hazardous, and there is a growing demand for PFAS-free coatings with high repellency against oils and fats.

Innovation Solution

A method involving plasma-enhanced chemical vapor deposition (PECVD) of halogen-free precursor monomers like organosilanes and siloxanes on woven polymeric fabrics with specific filament diameters and mesh openings, combined with additional treatments like DLC and APL, to achieve hydro- and oleophobic properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If PFAS (per- and polyfluorinated substances) are used to achieve hydro- and oleophobic properties, then water and oil repellency is improved, but environmental persistence and health hazards increase

Engineering Contradiction:

Improvehydro- and oleophobic propertiesVSAvoidenvironmental persistence and health hazards

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention extracts and removes the harmful fluorinated components (PFAS) from the coating formulation while retaining the essential hydro- and oleophobic functional properties through alternative non-fluorinated chemical structures and plasma deposition methods

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention changes the chemical composition parameters by substituting fluorinated compounds with alternative materials and modifies the deposition process parameters through plasma-enhanced chemical vapor deposition to achieve comparable repellency without harmful substances

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If short chain fluorocarbon (C3 to C1) compounds are used to reduce environmental impact, then regulatory compliance is improved, but hydro- and oleophobic performance decreases

Engineering Contradiction:

Improveenvironmental persistenceVSAvoidhydro- and oleophobic characteristics

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The invention uses composite plasma coatings combining organosilane and siloxane components that work synergistically to provide both hydrophobic and oleophobic properties, achieving performance comparable to or exceeding fluorinated coatings without environmental harm

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention changes the chemical composition from fluorinated to organosilicon-based compounds and utilizes plasma process parameters to achieve high-density crosslinked networks that provide superior repellency

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If plasma-enhanced chemical vapor deposition of halogen-free precursors is used, then environmental safety is improved, but achieving effective oleophobic properties becomes more difficult

Engineering Contradiction:

Improvehalogen-free compositionVSAvoidoleophobic performance

Core Design Contradiction:

Object-affected harmful factorsVSManufacturing precision

Solution Approach 1:

The invention employs composite plasma coatings combining organosilane and siloxane components that work synergistically to provide both hydrophobic and oleophobic properties, achieving performance comparable to or exceeding fluorinated coatings without environmental harm

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The plasma coating creates a controlled porous or microstructured surface morphology that enhances oleophobic properties through surface tension effects and capillary pressure, achieving effective oil and grease repellency with halogen-free composition

Inventive Principle:

Principle #31Porous materials

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 method produces fabrics with excellent hydrophobic and oleophobic characteristics, maintaining air permeability and durability, suitable for various applications including protective and filtration uses.

Implementation Method 1

A method involving plasma-enhanced chemical vapor deposition (PECVD) of halogen-free precursor monomers like organosilanes and siloxanes on woven polymeric fabrics

Methodology Applied

Scientific EffectPlasma-enhanced chemical vapor deposition: Plasma Enhanced Chemical Vapour Deposition

Data Source

PatentUS20250314007A1Method of producing a fabric having hydro- and oleophobic characteristics

Publication Date: 2025.10.09 SEFAR AG

AI summary

The invention relates to a method of producing a fabric having a halogen free plasma coating, having a hydro- and oleophobic characteristics, wherein the method comprises: step DHF of depositing a plasma coating on the fabric by means of plasma polymerization of a halogen free precursor monomer by plasma-enhanced chemical vapor deposition method (PECVD), wherein the halogen free precursor monomer are organosilane, siloxane and/or hydrocarbon precursors, wherein the plasma-enhanced chemical vapor deposition is carried out as a low-pressure plasma processes under protective atmosphere, wherein the fabric comprises of a woven monofilament fabric of polymeric material having a filament diameter between 10 μm to 150 μm and a mesh opening between 5 μm and 200 μm.