Plasma-Treated Fiber Coating for Durable Adhesion Without Water Waste
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Solution Overview
Problem
Existing methods for coating fiber assemblies and filaments are not robust, erode quickly, and require large amounts of water and harmful chemicals, with poor adhesion of colorants leading to inefficiencies and environmental concerns.
Innovation Solution
A process involving corona discharge plasma treatment to create gaps in fibrous strands, followed by exposure to ionic or acidic surfactants and thermoplastic polymers, which are then applied using an aero-diffusion device to ensure deep penetration and adhesion of the coating, minimizing waste and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional chemical coatings are applied to fiber assemblies and filaments, then aesthetic appearance and physical performance are improved, but the coatings are not robust and erode or abrade away quickly
Solution Approach 1:
The fiber surface undergoes preliminary plasma treatment and surfactant exposure before coating application. This preliminary action modifies the surface chemistry and creates gaps that enable the coating to penetrate deeply and adhere permanently, preventing erosion and extending coating lifespan
Solution Approach 2:
The invention creates a porous structure with gaps in the fiber surface through plasma treatment. These gaps allow coating material to penetrate into the fiber interior, creating a mechanically interlocked structure that significantly improves coating robustness and resistance to abrasion
2Ease of manufacture
If traditional coating methods are used, then coatings can be applied to fiber surfaces, but hundreds to thousands of liters of clean water and dozens of harmful chemicals are required per kilogram of material
Solution Approach 1:
The invention extracts and eliminates the need for large volumes of water and harmful chemicals from the coating process. By using plasma treatment and aerosol application, the process achieves effective coating without traditional wet processing steps that generate massive wastewater
Solution Approach 2:
The invention uses aerosol technology (pneumatic delivery system) to apply coating materials as fine mist particles. This pneumatic approach enables uniform coating distribution with minimal material usage, eliminating the need for water-based processing and chemical waste treatment
3Manufacturing precision
If traditional coloring processes are used with large water volumes and chemical dyes, then fiber assemblies can be colored, but penetration of color into the fiber surface is low and color can be removed through use
Solution Approach 1:
Plasma treatment is applied preliminarily to open gaps in the fiber surface structure before colorant application. This preliminary action enables deep penetration of color particles into the fiber interior, ensuring permanent coloring that cannot be easily removed through use or washing
Solution Approach 2:
The invention transitions from surface-level coloring to three-dimensional penetration by utilizing plasma-created gaps as pathways. Color particles are delivered deep into the fiber structure rather than remaining on the surface, achieving permanent incorporation of pigment
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
Results in a durable, long-lasting coating with enhanced adhesion and reduced material usage, improving both aesthetic and performance properties while minimizing environmental impact.
Implementation Method 1
the use of corona discharge plasma reconfiguration of fibrous strands to ensure that the surface area is appropriately adhesive and that gaps are created that permit the penetrative and durable coating to become permanently affixed to the fibrous strands
Implementation Method 2
the exposure of the fibrous strands to an ionic, anionic, or acidic surfactant solution that further enhances surface adhesion and enlarges the gaps
Implementation Method 3
Fibrous strands are then applied to an aero-diffusion device that applies a chemical mixture of coating material at a specific pressure to the top of the fibrous strands
Implementation Method 4
the use of a linear manufacturing system with elevated temperature and humidity to make sure electrical and chemical modification of the fibrous strands; preferably in the form of superstructures, filament assemblies, filaments or fibers become permanent and resistant to future oxidative, heat, or other insults
Data Source
AI summary
Provided is fibrous strand, and method of making a fibrous strand, comprising at least one filament wherein said filament comprises a surface with gaps in the surface. A cured thermoplastic polymer is on the surface wherein the cured thermoplastic polymer comprises a coating material and the cured thermoplastic polymer and coating material extend into the gaps.