Method for producing a carrier layer with a hydrophilic polymeric nanocoating

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Solution Overview

Problem

Current methods for producing hydrophilic thin films face challenges due to the lack of proper volatile precursors and difficulty in composition control, hindering the development of permanent hydrophilic functional groups for medical and hygienic applications.

Innovation Solution

A method involving low-pressure plasma polymerization using organic precursor monomers to create a hydrophilic polymeric nanocoating on a polymeric carrier layer, which forms a composite membrane with enhanced stability and functional properties through plasma-enhanced chemical vapor deposition (PECVD), allowing for high adhesion and retention of functional groups.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If conventional polymerization methods are used to produce hydrophilic thin films, then the process is relatively simple, but the functional groups cannot be permanently incorporated and composition control is difficult

Engineering Contradiction:

Improvepermanency of hydrophilic functional groupsVSAvoiddifficulty in composition control

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent applies plasma polymerization instead of conventional solution or melt polymerization, fundamentally changing the polymerization parameters and environment. This allows permanent incorporation of hydrophilic functional groups (carboxyl, hydroxyl, carbonyl) into the polymer network while maintaining precise composition control through selection of specific monomers and plasma conditions

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces conventional chemical or mechanical polymerization methods with plasma-induced polymerization. The plasma state provides unique reactive species and energy distribution that enables permanent functional group incorporation and precise composition control that cannot be achieved with traditional methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If plasma polymerization is used to create permanent hydrophilic functional groups, then the stability and functionality are improved, but the process complexity and equipment requirements increase

Engineering Contradiction:

Improvelong-term stability of hydrophilic surfaceVSAvoidplasma processing equipment

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent uses low-pressure plasma conditions with specific power densities and monomer concentrations to achieve permanent functional group incorporation. By optimizing these parameters, the process achieves high reliability and long-term stability of hydrophilic surfaces while managing the complexity of plasma equipment through systematic parameter control

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If a nanocoating layer is applied to enhance hydrophilicity and functionality, then the functional properties are improved, but the manufacturing cost and process steps increase

Engineering Contradiction:

Improvefunctional properties for medical applicationsVSAvoidcost-effectiveness

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent combines the coating application and functional group incorporation into a single plasma polymerization step. The nanocoating is deposited simultaneously with the formation of hydrophilic functional groups, eliminating separate functionalization steps and reducing overall manufacturing complexity and cost while maintaining high adaptability for medical applications

Inventive Principle:

Principle #5Merging (Combining)

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 method achieves a robust, reliable, and cost-effective production of hydrophilic fabrics and composite membranes with improved wettability, filtration efficiency, and long-term stability, suitable for medical, healthcare, and food applications.

Implementation Method 1

a polymeric hydrophilic nanocoating being produced according to the inventive method and forming a composite membrane, and a polymeric hydrophilic nanocoating is applied on the carrier layer and/or the composite membrane

Methodology Applied

Scientific EffectPlasma enhanced chemical vapor deposition: Plasma Enhanced Chemical Vapour Deposition

Data Source

PatentUS12186776B2Method for producing a carrier layer with a hydrophilic polymeric nanocoating

Publication Date: 2025.01.07 SEFAR AG

AI summary

A method for producing a carrier layer with a hydrophilic polymeric nanocoating wherein a polymeric carrier layer is produced with filaments of polymer material(s). The hydrophilic polymer nanocoating is applied with a low pressure plasma polymerization process using organic precursor monomers deposited onto the polymeric carrier layer and/or composite membrane. Additionally, a carrier layer includes a polymeric hydrophilic nanocoating.