Linker-Free Plasma Functionalization of Polyethylene Resin

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for functionalizing thermoplastic resins to gain specific properties, such as antibacterial and anti-odor functionalities, do not effectively form covalent bonds with active agents, limiting their stability and efficiency.

Innovation Solution

A linker- or initiator-free method involving plasma treatment of thermoplastic resins to introduce functional groups, followed by preservation and melt processing with active agents, enabling covalent bonding and enhancing the resin's functional properties without the need for additional coupling agents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional chemical or irradiation methods are used to functionalize thermoplastic resin surface, then functional properties can be obtained, but covalent bonding with active agents is not effectively formed, limiting stability and efficiency

Engineering Contradiction:

Improvebonding stabilityVSAvoidfunctionalization process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention changes the chemical parameters of the resin surface by introducing specific functional groups (carboxyl, hydroxyl, amino groups) through plasma treatment, enabling covalent bonding with active agents. This parameter change transforms the surface chemistry to achieve reliable covalent bonds without complex additional coupling agents

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces conventional chemical grafting methods with plasma treatment to introduce functional groups. Plasma treatment provides a more efficient and controllable method to create reactive sites on the resin surface, enabling direct covalent bonding with active agents like antimicrobial substances

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If plasma treatment is used to introduce functional groups, then covalent bonding capability is enabled, but functional groups may be lost or degraded without proper preservation

Engineering Contradiction:

Improvecovalent bonding capabilityVSAvoidfunctional groups stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The invention performs preliminary preservation of functional groups immediately after plasma treatment by conducting subsequent processing steps (mixing with active agents, molding) without exposing the treated resin to conditions that would degrade the functional groups. This preliminary action ensures the functional groups remain intact and reactive

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention uses an inert or controlled atmosphere during processing to prevent degradation of the plasma-introduced functional groups. By controlling the environmental conditions (avoiding excessive heat, oxidation, or moisture exposure before bonding), the functional groups are preserved and maintain their reactivity for covalent bonding

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Strength

If additional coupling agents or linkers are used to enhance bonding, then bonding strength may be improved, but production costs increase and material safety is compromised

Engineering Contradiction:

Improvebonding strengthVSAvoidchemical safety

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention extracts and eliminates the need for additional coupling agents or linkers by directly introducing functional groups onto the resin backbone through plasma treatment. This extraction of unnecessary intermediate substances simplifies the system, reduces costs, and improves material safety by removing potential harmful chemicals

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The resin itself is modified to possess the bonding capability through plasma-introduced functional groups, making the resin self-sufficient for covalent bonding with active agents. This self-service approach eliminates the need for external coupling agents, reducing complexity and improving safety

Inventive Principle:

Principle #25Self-service

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 results in a more stable and efficient bonding of active agents with thermoplastic resins, reducing production costs and minimizing decomposition, while providing a chemically safe material with wider applications, such as in food packaging, with improved antibacterial properties.

Implementation Method 1

pre-treating the thermoplastic resin or a mixture containing thereof with plasma in order to introduce functional groups to the backbone of the thermoplastic resin

Methodology Applied

Scientific EffectPlasma treatment: Plasma

Data Source

PatentUS10030108B1Initiator or linker free functionalization of polyethylene resin with antimicrobial property and methods of fabrication thereof

Publication Date: 2018.07.24 KA SHUL MANUFACTORY CO LTD

AI summary

The present invention generally relates to a thermoplastic resin which is functionalized by an initiator- or linker-free process and imparted with functional properties, and related methods of fabrication. In particular, the present invention relates to methods of covalently modifying the thermoplastic resin using plasma before or after being introduced with an active agent having said functional properties.