Non-Thermal Plasma Coating Uniformity via Solvent Spraying

The patent changes the fundamental parameter of plasma temperature by transitioning from thermal plasma (high temperature) to non-thermal plasma (low temperature). This allows the coating process to proceed at temperatures that do not damage temperature-sensitive materials while maintaining effective coating deposition capability through the reactive species present in non-thermal plasma.

The patent applies preliminary plasma treatment to the substrate surface before coating deposition. This preliminary action modifies the substrate surface properties (increasing surface energy, creating reactive groups) to ensure uniform nucleation and growth of the coating, thereby improving coating uniformity while maintaining efficient coating formation.

The patent creates a universal coating system that can handle both gas phase monomers and liquid phase macromolecules. The non-thermal plasma atmospheric pressure system provides a common platform that accommodates different material forms and sizes, enabling the same system to effectively coat everything from small monomer molecules to large macromolecular structures without requiring separate specialized equipment.

The patent segments the coating process into distinct stages: first, plasma treatment of the substrate surface to prepare it for coating; second, application of the coating material (aerosol or liquid); third, controlled plasma exposure to induce uniform crosslinking. This segmentation prevents premature reactions that cause non-uniformity while maintaining the benefits of immediate chemical reaction when properly timed.