Plasma-Cured Interpenetrated Polymer Network Synthesis

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Solution Overview

Problem

Existing methods for producing Interpenetrating Polymer Networks (IPNs) are limited by the need for multiple photo-initiators in UV curing and a restricted wavelength range, which is not suitable for biomaterials and can lead to phase separation issues.

Innovation Solution

A process involving the application of a mixture of a vinyl or allyl monomer and a polymerizable cyclic monomer on a substrate, where the vinyl or allyl monomer is cured using plasma to form an IPN without cross-reactions, allowing for in-situ sequential synthesis without chemical initiators and reversible radical transfer agents, and minimizing alteration of the second monomer's chemical structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If UV radiation curing is used to rapidly synthesize IPN coatings, then synthesis speed is improved, but the need for two different photo-initiators and limited wavelength range accessibility worsens the process complexity and restricts applicability to biomaterials

Engineering Contradiction:

Improvesynthesis speedVSAvoidneed for two different photo-initiators

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent extracts and removes the photo-initiator components from the UV curing system, replacing them with a plasma initiation mechanism. This eliminates the complexity of selecting and using two different photo-initiators while maintaining rapid curing capability through plasma-induced polymerization.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent substitutes the chemical initiation system (photo-initiators) with a physical initiation system (plasma). The plasma provides the energy required to initiate polymerization through physical means rather than chemical catalysts, thereby simplifying the overall system and expanding material compatibility.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Temperature

If UV radiation is used for curing, then rapid synthesis at room temperature is achieved, but the limited wavelength range and suitability for biomaterials synthesis worsens

Engineering Contradiction:

Improveroom temperature curingVSAvoidsuitability for biomaterials synthesis

Core Design Contradiction:

TemperatureVSAdaptability or versatility

Solution Approach 1:

The plasma initiation system provides universal applicability across different monomer types and biomaterial systems. Unlike UV curing which is restricted by wavelength compatibility with specific photo-initiators, plasma can initiate polymerization of a broad range of monomers including those suitable for biomaterials applications, thereby achieving multi-functionality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If a mixture of two or more pre-formed polymer networks is used, then synthesis is simplified, but the result is not a true IPN and phase separation problems occur

Engineering Contradiction:

Improvesynthesis simplicityVSAvoidphase separation

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent applies preliminary action by forming the first polymer network in situ within the monomer mixture before the second network is formed. This sequential in-situ formation ensures proper interpenetration and cross-linking of both networks, preventing phase separation while maintaining synthesis simplicity through the plasma initiation process.

Inventive Principle:

Principle #10Preliminary action

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 enables the production of IPNs with improved mechanical and thermal characteristics, increased thermal stability, and tailored properties by adjusting the monomer ratio, without the need for photo-initiators, and with enhanced char yield and scratch resistance.

Implementation Method 1

The produced short current discharge induces formation of free radicals that initiate the free radical polymerisation process

Methodology Applied

Scientific EffectFree radical polymerisation: Photopolymerisation

Implementation Method 2

step (c) comprises using a plasma so as to first cure the first monomer

Methodology Applied

Scientific EffectPlasma curing: Plasma

Data Source

PatentUS20240191097A1Interpenetrated polymer network produced by plasma

Publication Date: 2024.06.13 LUXEMBOURG INSTITUTE OF SCIENCE AND TECHNOLOGY (LIST)

AI summary

The invention is directed to a process of producing an interpenetrated network of at least two polymers; comprising the following steps:(a) preparing a mixture (10) comprising a first monomer and a second monomer;(b) applying the mixture (10) on a substrate (6); and(c) curing the first monomer and the second monomer so as to form the interpenetrated network;characterized in that the first monomer is a vinyl or allyl monomer; the second monomer is a polymerizable cyclic monomer; and step (c) comprises using a plasma (12) so as to first cure the first monomer.