Atmospheric Pressure Plasma Coating with UV-Curing Stabilization
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Solution Overview
Problem
Atmospheric pressure plasma coating methods often suffer from instability due to unreacted monomer residues in polymerizable precursor coatings, which affects the mechanical and chemical properties of substrates.
Innovation Solution
A method involving atmospheric pressure plasma deposition followed by UV-curing with wavelengths between 290nm and 400nm to convert unreacted precursors into polymer material, enhancing coating stability and cross-linking, using a combination of plasma-generated radicals and photoinitiator-induced radical formation for improved reactivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If atmospheric pressure plasma deposition is used to apply polymerizable precursor coatings, then coating application is simplified and industrialization becomes more feasible, but coating instability occurs due to unreacted monomer residues
Solution Approach 1:
The patent introduces UV light as an intermediary agent to mediate the conversion of unreacted monomer to polymer. The UV irradiation system acts as a mediator between the plasma deposition process and the final coating stabilization, enabling complete polymerization without requiring changes to the plasma process itself. This resolves the contradiction by adding a complementary process that addresses the instability issue while maintaining the simplicity of atmospheric pressure plasma deposition.
Solution Approach 2:
The patent applies UV irradiation as a preliminary or subsequent action to ensure complete polymerization of the coating. By pre-irradiating or post-irradiating the coated substrate, the unreacted monomer is converted to polymer before the coating is fully utilized, preventing instability issues. This preliminary action ensures coating stability is achieved proactively rather than reactively.
2Manufacturing precision
If low-pressure plasma treatment is used for surface modification and coating, then coating quality is improved, but reactor cost and investment requirements increase significantly
Solution Approach 1:
The patent changes the pressure parameter from low-pressure to atmospheric pressure in the plasma deposition process. This parameter change allows the use of simpler, more cost-effective equipment while maintaining coating quality through the addition of UV irradiation. The atmospheric pressure condition eliminates the need for complex vacuum systems and associated high costs, while UV irradiation ensures complete polymerization to maintain coating quality.
Solution Approach 2:
The patent replaces the mechanical/vacuum-based low-pressure plasma system with an atmospheric pressure plasma system enhanced by UV irradiation. The UV irradiation component substitutes for the complex vacuum maintenance and precision control required in low-pressure systems, achieving similar coating quality through a different physical mechanism that is more cost-effective and easier to implement industrially.
3Reliability
If UV-curing is applied after plasma deposition, then coating stability and cross-linking are enhanced, but additional process time and equipment are required
Solution Approach 1:
The patent merges the plasma deposition process with UV irradiation treatment in an integrated coating system. By combining these two processes, the unreacted monomer conversion is achieved within the same operational framework, reducing overall process time. The UV irradiation is applied either during or immediately after plasma deposition, eliminating separate processing steps and reducing total time investment while enhancing coating stability.
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 UV-curing step significantly stabilizes the coating, enhancing its strength, durability, and adhesion properties, as demonstrated by improved adhesion forces and reduced unreacted monomer presence.
Implementation Method 1
producing an atmospheric pressure plasma discharge in the presence of a gas, at least partially exposing the substrate to said atmospheric pressure plasma discharge
Implementation Method 2
plasma-generated radicals
Implementation Method 3
curing the substrate and coating, by exposing the substrate to ultraviolet light... convert unreacted precursors into polymer material... photoinitiator-induced radical formation
Data Source
Figure 1
AI summary
The present invention is related to a method of coating a substrate, said method comprising the steps of: providing a substrate (1), producing an atmospheric pressure plasma discharge in the presence of a gas, at least partially exposing the substrate to said atmospheric pressure plasma discharge, introducing a liquid aerosol (6) of coating forming material into said atmospheric pressure plasma discharge, thereby forming a coating on the substrate, curing the substrate and coating, by exposing the substrate to ultraviolet light.