Plasma Antimicrobial Coating for Substrates Without Wet Processing
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Solution Overview
Problem
Conventional wet processing techniques for applying antimicrobial coatings to substrates are environmentally unfriendly, energy-intensive, and can affect the physical properties of the substrate, while being difficult to scale up and limiting the variety of substrate materials.
Innovation Solution
A process using plasma treatment with surface dielectric barrier discharges to deposit antimicrobial active compounds on substrates, which enhances antimicrobial performance and maintains the substrate's physical properties, allowing for the use of virtually any substrate material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wet processing techniques are used to apply antimicrobial coatings, then antimicrobial properties are achieved, but environmental friendliness deteriorates due to large amounts of chemicals and solvents required
Solution Approach 1:
The invention changes the fundamental parameter of the deposition process from wet (liquid-based) to plasma (gas-phase) processing. This parameter change eliminates the need for large amounts of chemicals and solvents, thereby resolving the contradiction between achieving antimicrobial properties and reducing environmental impact.
Solution Approach 2:
The invention replaces the mechanical wet processing system (dipping, spraying, padding) with a plasma-based deposition system. This substitution uses plasma chemistry and physics to achieve coating deposition without the harmful chemicals and solvents associated with traditional wet methods.
2Reliability
If wet processing techniques are used to apply antimicrobial coatings, then antimicrobial properties are achieved, but energy consumption increases due to heating and drying steps
Solution Approach 1:
The invention changes the processing parameter from thermal (heating and drying) to plasma-based deposition. This eliminates the need for high-temperature heating and extended drying steps, significantly reducing energy consumption while maintaining antimicrobial coating effectiveness.
3Reliability
If wet processing techniques are used to apply antimicrobial coatings, then antimicrobial properties are achieved, but physical properties of the substrate deteriorate
Solution Approach 1:
The invention changes the deposition method from wet processing to plasma treatment, which operates under different physical parameters (gas phase, atmospheric or low pressure). This parameter change allows for controlled coating deposition that does not saturate or damage the substrate, preserving its physical properties while achieving antimicrobial functionality.
4Reliability
If wet processing techniques are used to apply antimicrobial coatings, then antimicrobial properties are achieved, but process complexity increases making scale-up difficult
Solution Approach 1:
The invention extracts and eliminates the complex multi-step wet processing sequence (pre-treatment, coating application, drying, curing) and replaces it with a simplified plasma-based process. This extraction of unnecessary steps reduces process complexity and facilitates easier scale-up.
Solution Approach 2:
The invention merges multiple separate wet processing steps into a single integrated plasma treatment step. This consolidation simplifies the overall process, reduces the number of equipment components needed, and makes scale-up more straightforward.
5Reliability
If wet processing techniques are used to apply antimicrobial coatings, then antimicrobial properties are achieved, but substrate material selection is limited
Solution Approach 1:
The invention creates a universal plasma treatment process that can be applied to virtually any substrate material (textiles, polymers, metals, ceramics). This universal approach eliminates the material-specific limitations of wet processing, allowing the same plasma deposition technique to effectively coat diverse substrates and achieve antimicrobial properties across different material types.
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 plasma treatment results in antimicrobial coatings with improved properties and reduced environmental impact, maintaining the substrate's original characteristics and enabling the use of a wide range of substrate materials, with enhanced antimicrobial activity and reduced operational costs.
Implementation Method 1
The plasma treatment comprises a plasma assisted grafting technique or a plasma induced polymerisation
Implementation Method 2
The plasma treatment comprises a plasma assisted grafting technique
Data Source
AI summary
The invention is directed to a process for preparing a substrate with an antimicrobial coating, and to a substrate with an antimicrobial coating. More, in particular the invention relates to a process in which an antimicrobial coating is prepared on the surface of a substrate using a plasma treatment. It was found that the process of the invention hardly affects the physical properties of the substrate, is environmentally friendly, uses high molecular weight non-toxic active compounds, and have improved antimicrobial activity compared to conventional wet processing techniques.