Apparatus for depositing a polymer coating containing nanomaterial on a substrate
Solution Overview
Problem
Existing methods for depositing nanoparticles on substrates, particularly in the textile industry, face limitations such as complex multi-step processes, environmental concerns due to harmful chemicals, high energy costs, and difficulty in achieving uniform deposition of non-metal nanoparticles, especially for soft and heat-sensitive materials like textiles.
Innovation Solution
A plasma polymerization method that involves providing a substrate with a flow containing nanomaterials, allowing for the deposition of virtually any type of nanomaterial, including non-metal types, using atmospheric pressure plasma processing, which is scalable and suitable for continuous on-line operation, and enables control over surface density and homogeneity of the deposited nanomaterial.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wet techniques such as sol-gel or dip coating are used to deposit nanoparticles, then a polymer matrix composite with nanoparticles can be created, but the process requires complicated multi-step procedures and is limited to certain types of nanoparticles
Solution Approach 1:
The invention extracts the nanoparticle deposition step from the complex multi-step wet processing sequence. By using atmospheric pressure plasma to directly deposit nanoparticles onto the substrate, the method eliminates the need for sol-gel preparation, dipping, drying, and curing steps, thereby simplifying the overall process while expanding nanoparticle type versatility
Solution Approach 2:
The invention replaces the mechanical wet processing system (dipping, spraying, coating) with a plasma-based deposition system. Atmospheric pressure plasma enables direct physical and chemical deposition of various nanoparticle types without requiring liquid carriers or complex chemical formulations, thus reducing procedural complexity while increasing adaptability
2Reliability
If wet processing methods are used to attach nanoparticles to textile fibers, then nanoparticles can be permanently attached to the material, but harmful chemicals and large amounts of water are required
Solution Approach 1:
The invention replaces wet chemical processing with atmospheric pressure plasma deposition. This substitution eliminates the use of harmful chemicals and large volumes of water while maintaining reliable nanoparticle attachment through plasma-induced surface activation and direct deposition mechanisms
Solution Approach 2:
The invention changes the processing parameters from liquid-phase chemical conditions to gas-phase plasma conditions. By operating at atmospheric pressure with reactive plasma species, the method achieves durable nanoparticle attachment without requiring harmful chemicals or extensive water usage, thus reducing environmental impact while maintaining reliability
3Manufacturing precision
If traditional plasma polymerization is used to deposit polymer layers, then a controlled polymer coating can be formed, but the process requires vacuum conditions and is not suitable for continuous production
Solution Approach 1:
The invention changes the pressure parameter from vacuum to atmospheric pressure conditions. This parameter change enables plasma polymerization to be performed in an open environment suitable for continuous production lines, while plasma control mechanisms maintain precise control over polymer coating formation and nanoparticle incorporation
Solution Approach 2:
The invention enables continuous plasma polymerization deposition by operating at atmospheric pressure. substrates can be continuously fed through the plasma reactor without interruption for vacuum pumping, allowing uninterrupted polymer coating formation and nanoparticle deposition, thus enabling continuous production while maintaining manufacturing precision
4Manufacturing precision
If high energy plasma processes are used to deposit nanomaterials, then uniform deposition can be achieved, but high energy may damage heat-sensitive materials like textiles
Solution Approach 1:
The invention changes the plasma energy parameters by operating at atmospheric pressure with controlled plasma power. This allows sufficient energy for uniform nanoparticle deposition while the atmospheric pressure condition and controlled plasma parameters prevent excessive heating that would damage heat-sensitive textile substrates
Solution Approach 2:
The atmospheric pressure environment acts as an intermediary that allows plasma energy to be delivered effectively for uniform deposition while dissipating excess heat to prevent substrate damage. The atmospheric pressure conditions enable controlled energy transfer that maintains deposition uniformity without causing thermal damage to sensitive materials
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 allows for the efficient and controlled deposition of nanomaterials on textiles, enhancing the performance of treated materials with improved chemical and physical properties, while reducing environmental impact and operational costs by eliminating the need for liquid baths and heating processes.
Implementation Method 1
depositing the polymer layer containing nanomaterial on the surface of the substrate material by applying a plasma polymerization process
Implementation Method 2
applying a plasma polymerization process
Data Source
AI summary
An apparatus for depositing a polymer layer containing nanomaterial on a substrate material includes a carrier for carrying the substrate material; a transport structure for providing a polymerization material near a surface of the substrate material and conducting a gas flow near the surface of the substrate material with the gas flow comprising a nanomaterial; and a plasma chamber wherein a plasma electrode structure is arranged for depositing the polymer layer containing nanomaterial on the surface of the substrate material by applying a plasma polymerization process.