Atmospheric Plasma Array for Uniform Surface Treatment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for applying low temperature atmospheric plasma (CAP) lack process control, resulting in non-uniform and non-repeatable treatment of surfaces, as they rely on manual movement of a single small plasma source without measurement or feedback control.
Innovation Solution
A system and method utilizing a plasma array with multiple atmospheric plasma sources, where each source is calibrated to deliver a predetermined dose distribution of reactive species across a treatment area through uniformity and dose modulation, ensuring consistent output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single small plasma source is manually moved over the treatment area, then the treatment can be applied to the surface, but the treatment uniformity and repeatability cannot be ensured
Solution Approach 1:
The plasma source is divided into multiple individual plasma elements arranged in an array, where each element can be independently controlled. This segmentation allows different zones of the treatment area to receive customized plasma exposure, ensuring uniformity across the entire surface while maintaining manageable system complexity through modular design.
Solution Approach 2:
The system implements dynamic control of each plasma element through individual on/off switching during scanning, allowing real-time adjustment of plasma delivery. This dynamic modulation compensates for variations in plasma output and ensures consistent treatment uniformity across the treatment area.
2Reliability
If manual movement of plasma source is used, then the system is simple to operate, but process control and measurement capability are lacking
Solution Approach 1:
The system incorporates sensors that detect plasma characteristics during treatment and feed this information back to the control system. This feedback mechanism enables automatic adjustment of plasma element activation patterns to maintain consistent treatment quality, ensuring reliable process control while the automated system handles the complexity of manual operation.
Solution Approach 2:
The manual mechanical movement of a single plasma source is replaced with an automated scanning system that controls multiple plasma elements electronically. This substitution eliminates the need for manual operation while providing precise control and measurement capabilities through electronic modulation and sensor integration.
3Manufacturing precision
If plasma output is not measured or controlled, then the system is simpler, but treatment repeatability cannot be achieved
Solution Approach 1:
The system performs preliminary calibration of each plasma element before actual treatment, establishing baseline output characteristics for each element. This preliminary measurement and characterization data is stored and used to guide subsequent treatment operations, ensuring repeatability without requiring continuous complex measurements during each treatment process.
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 system achieves uniform and repeatable plasma treatment by calibrating and modulating the output of each plasma element, ensuring consistent delivery of reactive species across the treatment area.
Implementation Method 1
Low temperature atmospheric plasma or cold atmospheric plasma (CAP) has been applied to surfaces to achieve biological effects
Implementation Method 2
Most common atmospheric plasma sources are dielectric barrier discharges (DBD), which use AC voltages or voltage pulses to create the plasma
Implementation Method 3
The reactive species output from each plasma element is measured, and an empirical element scaling factor is derived for each plasma element
Data Source
AI summary
Disclosed is a system and method for delivering reactive species from a plasma to a treatment area by scanning a linear array of stacked plasma elements across the treatment area. Reactive species output from each plasma element is calibrated, and during scanning each plasma element is modulated with a uniformity modulation and a dose modulation, enabling a predetermined contour dose distribution of reactive species to be delivered to the treatment area.