Innovative, bio-based plasma coatings on micro- to nano-structured surfaces for microfluidic and riblet applications
Innovative surfaces and coatings for fluid dynamic applications are highly desired in various industry sectors like food, cosmetic and paper production. While the bio-mimicking structured surface specifies a flow-optimized basis, further functionalities like durable antimicrobial and hydrophilic/hydrophobic properties implies additional coatings. This poses the challenge of addressing the sophisticated functionality of the surface appropriate to the end-use while reducing raw material use and saving energy for its application. Furthermore, the substitution of fossil-based feed stock with bio-based, renewable resources is postulated related to Sustainable Development Goals and Responsible Research and Innovation (RRI) requirements. Complementary, the optimization of structured surfaces in terms of energy-efficient use and recyclability of end-products addresses circular economy aspects as well as goals of the European Green Deal.
The InnoCoat4Plasma project aims at the development of bio-based coatings with renewable, functionalized additives able to improve the technological and antimicrobial properties of imprinted thermoplastic foils for microfluidic and riblet applications, polymerized and deposited by means of atmospheric plasma techniques supported by multiscale modelling.
The project concept combines bio-based coating formulations and bio-based/recycled thermoplastic foils with imprinted micro- to nanostructures towards an environmentally friendly deposition approach involving a reduced amount of chemical by-products generation and lower energy consumption. The development of non-hazardous atmospheric plasma coatings comprises the use of bio-based pre-polymers from plant oils, and renewable fillers such as Betulin extracts from birch bark to tailor the properties for microfluidics and riblet applications, e.g. enabling oil-in-water (hydrophilic coating) and water-in-oil (hydrophobic coating) droplet generation as well as anti-biofilm surfaces for riblets in processing industry environments.
In addition, the project enables the functionalization of sustainable particles using plasma techniques to enhance their dispersibility and compatibility with matrix polymers. These challenging technical and scientific tasks are supported by simulation and multiscale modelling of plasma processes (interaction plasma/surface, film formation), new nozzle designs for selective plasma micro-structuring and investigations of structured surfaces in contact with different liquid media. To demonstrate the potential of the plasma-polymerized functional bio-based coatings for industrial applications, trials and characterization will be carried out supplemented by two demonstrator applications.
The InnoCoat4Plasma project unites advanced material design and high-efficient manufacturing concepts that will generate more competitive products. Bio-based coating solutions are postulated from societal, sustainability and RRI requirements including efficient application methods. Recyclable products with high energy-efficiency considering circular economy aspects are of high interest in several economic sectors. The project will enable novel expertise, multidisciplinary research, and innovation in the field of plasma-polymerized bio-based coatings on optimized structured surfaces and will establish new strategic collaborations, encouraging the competitiveness of the partners. The interdisciplinary consortium from research and industry with project-relevant know-how will contribute to advance the research and to deliver feasible solutions to the market with significantly improved ecological impacts.
The project recieved funding from the Luxembourg National Research Fund (FNR) through the Advanced Material M-ERA.NET call 2024 (INTER/MERA24/19101873/InnoCoat4Plasma).
