Plasma Polymer Mixed Layer Adhesion

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Solution Overview

Problem

Existing methods for improving adhesion between a substrate and a cover layer, particularly with plasma polymer layers, lack clarity on the production process and effectiveness, especially for materials with poor adhesive properties like polyolefins and organofluorine polymers, and often rely on solvent-based adhesion promoters.

Innovation Solution

A composite structure comprising a substrate, a plasma polymer layer, and a cover layer with a mixed layer in between, where the plasma polymer layer is deposited in a reactive oligomeric state that mixes with the cover layer material, forming a transition zone with enhanced adhesion properties, achieved through controlled plasma-enhanced chemical vapor deposition (PECVD) and specific deposition conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a plasma polymer layer is deposited to improve adhesion between substrate and cover layer, then adhesion properties are improved, but the process complexity and lack of precise production information increase

Engineering Contradiction:

Improveadhesion propertiesVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention changes the deposition parameters by controlling the plasma polymerization process to stop at specific time points, creating layers with different degrees of polymerization (oligomeric vs. polymeric state). This parameter control allows tuning of adhesion properties without adding process steps

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The plasma polymer layer is deposited in advance in a controlled oligomeric state with reactive groups, preparing the surface for subsequent cover layer application. This preliminary action ensures optimal adhesion conditions are established before the cover layer is applied

Inventive Principle:

Principle #10Preliminary action

2Reliability

If solvent-based adhesion promoters are used to ensure sufficient adhesion, then adhesion stability is improved, but environmental harm and health risks increase

Engineering Contradiction:

Improveadhesion stabilityVSAvoidenvironmental harm

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The invention replaces chemical solvent-based adhesion promoters with a plasma-based physical/chemical deposition process. The plasma polymer layer provides adhesion promotion through controlled polymerization and reactive group formation, eliminating the need for harmful organic solvents

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The plasma deposition process occurs in a controlled atmosphere (vacuum or inert gas environment), eliminating the need for solvent-based promoters that require handling in potentially harmful chemical environments

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Stability of the object's composition

If the plasma polymer layer is fully polymerized to achieve stable structure, then structural stability is improved, but adhesion reactivity decreases

Engineering Contradiction:

Improvestructural stabilityVSAvoidadhesion reactivity

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The plasma polymerization process is intentionally stopped at a partial stage, creating an oligomeric layer with retained reactive groups rather than allowing complete polymerization. This partial action maintains both structural integrity and adhesion reactivity

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The invention creates a dynamic system where the plasma polymer layer can be deposited with controlled degrees of polymerization, allowing adjustment between structural stability and adhesion reactivity based on application requirements

Inventive Principle:

Principle #15Dynamics

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 approach ensures strong, media-stable adhesion between the substrate and cover layer, replacing solvent-based promoters and promoting adhesion without the need for additional layer applications, with the mixed layer facilitating chemical reactivity and improved bonding.

Implementation Method 1

achieved through controlled plasma-enhanced chemical vapor deposition (PECVD) and specific deposition conditions

Methodology Applied

Scientific EffectPlasma-enhanced chemical vapor deposition (PECVD): Plasma Enhanced Chemical Vapour Deposition

Implementation Method 2

a plasma polymer layer... deposited from a precursor by a plasma process

Methodology Applied

Scientific EffectPlasma polymerization: Plasma

Data Source

PatentEP3200931B1Composite consisting of a substrate, a plasma polymer layer, a mixed layer and a cover layer

Publication Date: 2022.08.24 FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV

AI summary

The present invention relates to a composite consisting of a substrate, a plasma polymer layer, a cover layer and a mixed layer arranged between the cover layer and the plasma polymer layer. The invention further relates to the use of a plasma polymer layer and a mixed layer to improve adhesion between a substrate and a cover layer, and to a method for producing a corresponding mixed layer.