Hybrid Plasma Surface Treatment for Deeper Material Modification
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Solution Overview
Problem
Current surface treatment methods for materials like textiles, which rely on single energy sources such as atmospheric plasma, are limited in their ability to effectively alter both the surface and core properties, and do not efficiently achieve desired properties like hydrophilicity, fire retardancy, and dyeability without significant chemical usage or environmental impact.
Innovation Solution
Combining high voltage generated atmospheric plasma with laser irradiation as secondary energy sources to create a hybrid plasma treatment that can alter both surface and core properties of materials, using a controlled atmospheric environment with inert gases and precursor materials to achieve enhanced functional properties like hydrophilicity, fire retardancy, and improved dyeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If single energy source (atmospheric plasma) is used for surface treatment, then surface properties can be improved, but the ability to alter core properties is limited
Solution Approach 1:
The patent combines atmospheric plasma with laser irradiation to create a hybrid treatment system. The plasma provides surface activation and chemical modification while the laser penetrates deeper into the material to alter core properties, achieving comprehensive material modification that neither energy source could accomplish alone.
2Reliability
If chemical treatments are used to achieve desired material properties, then functional properties can be improved, but environmental impact and chemical usage increase
Solution Approach 1:
The patent replaces chemical treatment systems with a physical hybrid energy system combining atmospheric plasma and laser irradiation. This substitution eliminates the need for harmful chemical substances while achieving the same or superior functional properties through controlled energy interaction with the material.
Solution Approach 2:
The atmospheric plasma is generated in a controlled atmosphere using inert or environmentally benign gases, replacing harmful chemical treatments with a cleaner process that reduces environmental impact while maintaining effective material modification for hydrophilicity, fire retardancy, and dyeability.
3Productivity
If atmospheric plasma is used for continuous processing, then productivity can be improved, but the depth of material modification is limited
Solution Approach 1:
By merging atmospheric plasma with laser irradiation, the system maintains the continuous processing advantage of plasma while adding the deep penetration capability of laser. The laser component enables modification at greater depths and throughout the material bulk, complementing the surface-level effectiveness of plasma treatment.
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 hybrid plasma treatment method enables more effective and efficient alteration of material properties, reducing chemical usage and environmental impact while achieving enhanced hydrophilicity, fire retardancy, and improved dyeability, making it suitable for a wide range of materials including textiles and other substrates.
Implementation Method 1
at least two combined mutually interacting energy sources such as laser and high voltage generated atmospheric (AP) plasma
Implementation Method 2
high voltage generated atmospheric (AP) plasma
Implementation Method 3
laser and high voltage generated atmospheric (AP) plasma
Implementation Method 4
activating by way of radical formation on the surface(s)
Data Source
Figure 1~2
Figure 2A~3
Figure 4A~4B
AI summary
Material treatment is effected in a treatment region (124) by at least two energy sources, such as (i) an atmospheric pressure (AP) plasma and (ii) an ultraviolet (UV) laser directed into the plasma and optionally onto the material being treated. Precursor materials (323) may be dispensed before, and finishing material (327) may be dispensed after treatment. Electrodes (e1, e2) for generating the plasma may comprise two spaced-apart rollers (212/214; 412/414; 436/438). Nip rollers (416/418; 436/438) adjacent the electrode rollers (412/414) define a semi-airtight cavity (440), and may have a metallic outer layer (437/439).