Atmospheric Plasma Coating for Aircraft Window Repair
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Solution Overview
Problem
Aircraft windows made from stretched acrylic are prone to wear from airborne particles and chemical agents, and existing abrasion-resistant coatings applied using flow-coating techniques require significant cure time, are susceptible to particulate damage, and are not amenable to in-service or in-field repair.
Innovation Solution
The method involves generating an atmospheric plasma and introducing a cyclic organosilane precursor to deposit a silicon oxy-carbide coating onto transparent polymeric substrates using an atmospheric plasma device, eliminating the need for flow-coating and vacuum systems, and allowing for in-field repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flow-coating techniques are used to apply abrasion-resistant coatings, then the coating can be applied to transparent polymeric substrates, but the process requires significant cure time and is not amenable to in-service or in-field repair
Solution Approach 1:
The patent changes the fundamental parameters of the coating process by transitioning from liquid flow-coating to atmospheric plasma deposition. This involves changing the deposition environment from ambient to plasma state, the coating mechanism from solvent-based to vapor-phase chemical reaction, and the curing process from thermal curing to plasma-induced crosslinking. These parameter changes enable immediate coating formation without extended cure times and allow for field repair applications.
Solution Approach 2:
The patent replaces the mechanical flow-coating system with an atmospheric plasma deposition system. Instead of using pumps, flow controllers, and curing ovens, the invention uses plasma generation electrodes, precursor gas delivery, and atmospheric plasma chemistry to deposit and crosslink the coating in situ. This substitution eliminates the time-consuming cure cycle and enables portable field repair capabilities.
2Ease of manufacture
If flow-coating techniques are used to apply abrasion-resistant coatings, then the coating can be applied to transparent polymeric substrates, but the process is susceptible to particulate/dust damage during the curing process
Solution Approach 1:
The patent performs preliminary plasma treatment of the substrate surface before coating deposition. This preliminary plasma exposure activates the substrate surface, creates surface energy for improved adhesion, and removes organic contaminants. By preparing the surface in advance through plasma treatment, the coating achieves better bonding and resistance to particulate damage without requiring extended cure times in controlled environments.
Solution Approach 2:
The patent changes the deposition environment from ambient air (prone to particulate contamination during slow curing) to atmospheric plasma state. The plasma environment provides a controlled reaction zone where coating precursors decompose and deposit rapidly on the substrate surface, completing the coating process in seconds rather than hours, thereby eliminating exposure to particulate contamination during curing.
3Stability of the object's composition
If sol-gel coatings are used with increased organic groups to improve flexibility, then the flexibility is improved, but wear durability is compromised
Solution Approach 1:
The patent applies local quality by creating a coating with spatially varying composition and properties. The atmospheric plasma deposition process allows different regions of the coating to have different organic-inorganic ratios, crosslinking densities, and functional group concentrations. This enables the coating to simultaneously exhibit flexibility near the substrate interface and enhanced wear durability at the exposed surface, resolving the trade-off between these conflicting properties.
Solution Approach 2:
The patent creates a composite coating structure combining organic silane precursors with inorganic plasma-derived components. The resulting coating contains both organic flexible segments and inorganic crosslinked networks, forming a composite material that exhibits both flexibility and wear durability. The plasma process enables controlled incorporation of both material types, creating a synergistic composite that overcomes the limitations of purely organic sol-gel coatings.
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 provides coatings with improved hardness and flexibility, reducing application time and equipment needs, enabling field repairs and compatibility with non-vacuum components, while enhancing wear resistance and durability against ultraviolet degradation.
Implementation Method 1
generating an atmospheric plasma, introducing a precursor to the atmospheric plasma, the precursor being selected to form the abrasion-resistant coating, and positioning the substrate relative to the atmospheric plasma such that the atmospheric plasma deposits the abrasion-resistant coating onto the substrate
Data Source
AI summary
A method for applying an abrasion-resistant coating to a substrate including the steps of generating an atmospheric plasma, introducing a precursor to the atmospheric plasma, the precursor being selected to form the abrasion-resistant coating, and positioning the substrate relative to the atmospheric plasma such that the atmospheric plasma deposits the abrasion-resistant coating onto the substrate.