Nanosensor Deposition on Low Surface Energy Substrates
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Solution Overview
Problem
Low surface energy materials pose challenges for nanosensor deposition due to weak interactions with adhesive ink and coatings, requiring surface energy modification to ensure proper wettability and bonding for effective nanosensor placement.
Innovation Solution
A method involving plasma stream treatment to increase the surface energy of low energy substrates from 10 mN/m to 80 mN/m, followed by electrostatic force-assisted deposition of nanosensors using an adhesive layer, utilizing a plasma energy treatment station with a plasma generator, heating element, and AFM probe for precise surface energy measurement and modification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If low surface energy materials are used for non-fouling surfaces, then anti-bacterial and anti-staining properties are improved, but adhesion of adhesive ink and coating materials deteriorates
Solution Approach 1:
The patent applies plasma treatment to the low surface energy substrate before applying the adhesive ink layer. This preliminary surface modification increases the surface energy of the substrate, creating a surface that can properly adhere to the adhesive ink while maintaining the bulk material's non-fouling properties. The plasma treatment is performed in advance to prepare the surface for subsequent coating operations.
Solution Approach 2:
The plasma treatment modifies only the surface layer of the substrate, creating a localized region with different properties (higher surface energy) while the bulk material retains its original low surface energy and non-fouling characteristics. This allows the surface to adhere to adhesives while the bulk material maintains anti-bacterial and anti-staining properties.
2Manufacturing precision
If surface treatment is applied to increase surface energy, then wettability and bonding are improved, but process complexity increases
Solution Approach 1:
The patent replaces complex chemical surface treatment processes with plasma treatment, which uses ionized gas to modify the surface. This substitution simplifies the overall process by using a more controllable and cleaner method that doesn't require extensive chemical handling, solvents, or multiple processing steps associated with traditional chemical treatments.
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
This approach enhances the sensitivity of nanosensors by improving adhesion and allowing for precise, site-specific deposition on low surface energy materials, ensuring reliable and accurate sensing capabilities.
Implementation Method 1
directing a plasma stream onto a low energy substrate to increase the surface energy of the substrate
Implementation Method 2
depositing nanosensors on the adhesive coated substrate via electrostatic force assisted deposition using a high strength electrostatic field
Data Source
AI summary
A system and method is provided for depositing nanosensors including directing a plasma stream onto a low energy substrate having a surface energy of from 10 mN/m to 43 mN/m to increase the surface energy of the substrate to from 44 mN/m to 80 mN/m, applying an adhesive layer to the plasma discharge treated substrate; and depositing nanosensors on the adhesive coated substrate of step (b) via electrostatic force assisted deposition using a high strength electrostatic field of from 2 kV/cm to 10 kV/cm to form vertically standing nanosensors.