Method of producing an object having a fluorinated polymer coating
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Solution Overview
Problem
Plasma deposition processes using fluorinated precursors can result in objects with significant amounts of per- and polyfluorinated acids and salts, which are environmentally harmful and regulated, due to the formation of these compounds when free radicals react with oxygen during and after the deposition process.
Innovation Solution
A method involving plasma polymerization of fluorinated precursors followed by exposure to an inhibiting gas, such as hydrogen or nitrogen, in a substantially oxygen-free atmosphere to prevent the formation of per- and polyfluorinated acids and salts, along with the use of non-fluorinated polymer coatings to enhance hydrophobic and oleophobic properties without the drawbacks of fluorinated compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If plasma deposition process uses fluorinated precursors, then hydrophobic and oleophobic properties are improved, but per- and polyfluorinated acids and salts are formed which are environmentally harmful
Solution Approach 1:
The patent applies preliminary anti-action by introducing an inhibiting gas (such as hydrogen or nitrogen) during the plasma deposition process to prevent the formation of per- and polyfluorinated acids and salts before they can form. This proactive approach stops the harmful chemical reactions at their inception while maintaining the beneficial fluorinated coating properties
Solution Approach 2:
The patent creates an inert atmosphere by using specific plasma conditions and inhibiting gases that prevent oxygen from reacting with fluorinated radicals during deposition. This controlled atmosphere eliminates the formation pathway for perfluorinated acids while allowing the fluorinated polymer coating to form with desired hydrophobic and oleophobic characteristics
2Ease of manufacture
If classical wet chemical polymerization is used, then coating process is simple, but non-uniform coatings and impurities from solvent are produced
Solution Approach 1:
The patent replaces wet chemical polymerization with plasma-enhanced chemical vapor deposition (PECVD). This substitution eliminates liquid solvents and their associated impurities, while producing uniform, pinhole-free coatings through controlled plasma polymerization of fluorinated precursors in the vapor phase
Solution Approach 2:
The patent changes the physical state of the polymerization process from liquid-phase wet chemistry to vapor-phase plasma processing. This parameter change eliminates solvent-related impurities and achieves superior coating uniformity while maintaining processability through controlled plasma conditions
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 effectively reduces and prevents the formation of per- and polyfluorinated acids and salts, achieving a fluorinated polymer coating that meets regulatory standards and provides improved hydrophobic and oleophobic characteristics without environmental contamination.
Implementation Method 1
plasma polymerization or plasma deposition processes have been a vibrant area of research as it provides a versatile route to design materials with tunable functionalities
Implementation Method 2
The energy input generates then excited electrons during glow discharge and lead to break molecules into free electrons, ions, radicals and excited molecules
Implementation Method 3
In a later stage these free radicals and excited molecules recombine, condense and polymerize on the substrate
Implementation Method 4
these free radicals and excited molecules recombine, condense and polymerize on the substrate
Implementation Method 5
the ions and electrons crosslink or form chemical bonds with the already deposited polymer
Implementation Method 6
the object is exposed to an inhibiting gas which inhibits the formation of per- and polyfluorinated acids and salts thereof in or on the deposited fluorinated coating
Data Source
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AI summary
The invention relates to a method of producing an object having a fluorinated polymer coating free of per- and polyfluorinated acids and salts thereof, wherein the method comprises a step DF of depositing a fluorinated polymer coating on the object by means of plasma polymerization of a fluorinated precursor monomer and a step IG of exposing the object to an inhibiting gas which inhibits the formation of per- and polyfluorinated acids and salts thereof in or on the deposited fluorinated coating. Thereby step IG is carried out after step DF, and from the start of step DF until the end of step IG the object is treated in a substantially oxygen free atmosphere.