Plasma-Bonded Chromic Substrates to Prevent Dye Leaching
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Solution Overview
Problem
Existing methods for coloring materials face challenges with dye leaching, particularly in inert materials like PET and PTFE, leading to color loss and potential contamination, and require complex synthesis or are restricted to specific substrate types, limiting their applicability.
Innovation Solution
A post-fabrication plasma surface modification method that covalently links a functionalized dye with a radical sensitive or polymerizable group to the substrate surface using a gas plasma treatment, allowing for durable coloration without interfering with the substrate's fabrication process and applicable to various materials and dyes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dye is absorbed by the material using simple staining method, then the coloring process is straightforward and generally applicable, but significant dye leaching occurs when the material is contacted with liquid
Solution Approach 1:
The patent creates a composite structure where dye molecules are covalently bonded to the polymer matrix through functional groups. This composite approach combines the dye with the substrate at the molecular level, preventing leaching while maintaining ease of application through dip-coating or spray methods.
Solution Approach 2:
The patent replaces physical absorption (weak van der Waals forces) with chemical bonding (covalent bonds) to immobilize the dye. This substitution of the binding mechanism eliminates dye leaching while keeping the coloring process simple and applicable to various materials.
2Loss of substance
If covalent linkage is achieved through copolymerization with functionalized dye, then dye leaching is completely suppressed, but complex synthesis and optimization are required
Solution Approach 1:
The patent incorporates reactive functional groups (vinyl, epoxy, isocyanate, isothiocyanate) into the dye molecules beforehand. This preliminary functionalization enables direct covalent bonding during simple dip-coating or spray processes, eliminating the need for complex copolymerization synthesis while achieving complete dye leaching suppression.
Solution Approach 2:
The patent changes the chemical parameters of the dye by introducing reactive functional groups that can form covalent bonds with the polymer matrix. This parameter change enables simple one-step coloring processes to achieve the same effect as complex multi-step copolymerization, reducing synthesis complexity while maintaining complete dye immobilization.
3Loss of substance
If specific surface functionalities are incorporated to achieve covalent linkage, then dye immobilization is achieved, but the approach is restricted to reactive surfaces
Solution Approach 1:
The patent uses plasma treatment to create universal reactive surface groups (hydroxyl, carboxyl, amine) on diverse inert substrates like PET, PTFE, and PP. This enables a single dye functionalization strategy to work across multiple substrate types, achieving both dye immobilization and broad substrate compatibility.
Solution Approach 2:
The patent introduces plasma treatment as an intermediary step that modifies inert substrate surfaces to create reactive functional groups. This intermediary process enables covalent bonding between dyes and previously non-reactive substrates, expanding substrate compatibility while maintaining effective dye immobilization.
4Loss of substance
If plasma treatment is applied to covalently link functionalized dye, then dye leaching is prevented, but the process requires functionalized dye synthesis
Solution Approach 1:
The patent incorporates reactive functional groups into the dye structure beforehand through simple chemical functionalization. This preliminary action enables the dye to form covalent bonds with plasma-treated substrates during straightforward dip-coating or spray processes, achieving complete dye leaching prevention without requiring complex synthesis or optimization.
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 method effectively prevents dye leaching, reduces the need for complex synthesis, and allows for the use of a wide range of substrates and dyes, providing a cost-effective and efficient method for creating colored or chromic substrates with stable color properties.
Implementation Method 1
subjecting the substrate and the coloring agent to radical species from a plasma generated by an atmospheric plasma apparatus
Implementation Method 2
until the coloring agent is set at the surface of the substrate
Data Source
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AI summary
The present invention provides a post-fabrication modification approach for the fabrication of colored and chromic materials and sensors using plasma surface modification to covalently bind the coloring agent to the substrate, thus avoiding leaching of the dye. Advantageously, in said methods, said coloring agent is a dye or pigment linked to a radical sensitive functional group, such as an alkenyl or alkynyl functional group, and is applied to the substrate prior to the gas plasma treatment. The methods envisaged herein are generic in nature, which allow the covalent immobilization of various dyes on different materials. The covalently coated materials after plasma surface modification, particularly the covalently coated chromic materials and sensors, can be used in many different applications, such as protective textile and wound dressing applications.