PLASMA TECHNOLOGY FOR HYPERFUNCTIONAL SURFACES
CONTENTS PART I INTRODUCTION TO PLASMA TECHNOLOGY FOR SURFACE FUNCTIONALIZATION INTRODUCTION TO PLASMA AND PLASMA TECHNOLOGY PLASMA: THE FOURTH STATE OF MATTER HISTORICAL HIGHLIGHTS PLASMA FUNDAMENTALS FREE IDEAL GAS INTERACTING GAS THE PLASMA AS A FLUID WAVES IN PLASMAS RELEVANT PARAMETERS THAT CHARACTERIZE THE STATE OF PLASMA CLASSI?CATION OF TECHNOLOGICAL PLASMAS HOT (THERMAL) PLASMAS AND THEIR APPLICATIONS COLD (NONTHERMAL) PLASMAS AND THEIR APPLICATIONS REACTIVE PLASMAS ELEMENTARY PLASMA–CHEMICAL REACTIONS ELASTIC SCATTERING AND INELASTIC THOMSON SCATTERING: IONIZATION CROSS-SECTION MOLECULAR IONIZATION MECHANISMS STEPWISE IONIZATION BY ELECTRON IMPACT PLASMA SHEATHS SUMMARY REFERENCES PLASMA SYSTEMS FOR SURFACE TREATMENT INTRODUCTION LOW PRESSURE PLASMA SYSTEMS MICROWAVE SYSTEMS STANDARD MICROWAVE SYSTEM FOR TEXTILE TREATMENT EXAMPLE: DUO-PLASMALINE–A LINEARLY EXTENDED PLASMA SOURCE ELECTRON CYCLOTRON RESONANCE HEATED PLASMAS CAPACITIVELY COUPLED SYSTEMS CAPACITIVE COUPLED PLASMA FOR BIOMEDICAL APPLICATIONS PHYSICAL VAPOR DEPOSITION PLASMA: LARC? BACKGROUND CATHODIC ARC PVD SYSTEMS EXAMPLE: TREATMENT OF FOOD PROCESSING TOOLS BY LARC? PVD SYSTEM ATMOSPHERIC PRESSURE PLASMA SYSTEMS CORONA-TYPE SURFACE TREATMENT STANDARD CORONA TREATMENT CONTROLLED ATMOSPHERE CORONA TREATMENT–ALDYNE TREATMENT LIQUID DEPOSITION REMOTE SURFACE TREATMENT PLASMA SOURCES USED FOR MODELING EXAMPLE: ACXYS PLASMA JET ACKNOWLEDGMENT PLASMA-SURFACE INTERACTION POLYMER ETCHING PLASMA GRAFTING CHEMICAL KINETICS CHAIN POLYMERIZATION PLASMA POLYMERIZATION EXAMPLE: PLASMA POLYMERIZATION PLASMA POLYMERIZATION OF HEMA THEORETICAL BACKGROUND EXAMPLE: POLYMERIZATION OF HEMA ON PET FABRIC PLASMA POLYMERIZATION OF HDMSO CONCLUSION PROCESS DIAGNOSTICS BY OPTICAL EMISSION SPECTROSCOPY OPTICAL EMISSION SPECTROSCOPY THEORY OF OPTICAL EMISSION SPECTROSCOPY OES BENCH AND SET-UP OPTICAL ABSORPTION SPECTROSCOPY ACTINOMETRY LASER INDUCED FLUORESCENCE (LIF) SURFACE ANALYSIS FOR PLASMA TREATMENT CHARACTERIZATION INTRODUCTION TO SURFACE CHARACTERIZATION TECHNIQUES X-RAY PHOTOELECTRON SPECTROSCOPY (XPS) OR ELECTRON SPECTROSCOPY FOR CHEMICAL ANALYSIS (ESCA) PRINCIPLES OF XPS XPS CORE LEVEL CHEMICAL SHIFT QUANTITATIVE ANALYSIS QUANTITATIVE ANALYSIS OF NITROGEN PLASMA-TREATED POLYPROPYLENE ANGLE-RESOLVED XPS DEPTH PRO?LING AND SURFACE SENSITIVITY ENHANCEMENT BY GRAZING ANGLE XPS DETECTION DETERMINATION OF THIN COATING THICKNESS BY ANGLE-RESOLVED XPS MAPPING SUMMARY OF XPS STATIC SECONDARY ION MASS SPECTROMETRY BY TIME OF FLIGHT (TOF-SSIMS) PRINCIPLES OF TOF-SSIMS SECONDARY ION EMISSION STATIC AND DYNAMIC MODES MOLECULAR SIMS APPLICATIONS OF TOF-SSIMS SPECTROMETRY MODE SECONDARY ION IMAGING DEPTH PRO?LING DATA TREATMENT BY MULTIVARIATE METHODS: MULTI-ION SIMS EXAMPLES POLY(ETHYLENE TEREPHTHALATE) TISSUE POLYPROPYLENE PACKAGING SIOX BARNER COATING ON PET ANTI-UV ADDITIVE QUALI?CATION ON PET FILMS ATOMIC FORCE MICROSCOPY OPERATING MODES IN AFM CONTACT MODE CONSTANT FORCE MODE RESONANT MODES THE CONTACT –NO CONTACT MODE PHASE CONTRAST MODE OTHER MODES SUMMARY AND OUTLOOK SCANNING ELECTRON MICROSCOPY (SEM) PRINCIPLES OF SEM IMAGING IN SEM NEW GENERATION OF SEM CHEMICAL ANALYSIS SAMPLE PREPARATION AND APPLICATIONS TRANSMISSION ELECTRON MICROSCOPY (TEM) PRINCIPLES OF TEM RESOLUTION IMAGE CONTRAST TYPICAL APPLICATIONS OF TEM SAMPLE REQUIREMENTS CONTACT ANGLE MEASUREMENT SURFACE ENERGY CALCULATION OWENS AND WENDT MODEL FOR SURFACE ENERGY CALCULATION GOOD AND VAN OSS MODEL FOR SURFACE ENERGY CALCULATION CONCLUSIONS PART II HYPERFUNCTIONAL SURFACES FOR TEXTILES, FOOD AND BIOMEDICAL APPLICATIONS TUNING THE SURFACE PROPERTIES OF TEXTILE MATERIALS POTENTIAL IMPACT OF PLASMA ON THE TEXTILE INDUSTRY PLASMA BASICS FUNDAMENTAL ADVANTAGE OF PLASMA PROCESSING CLASSI?CATION OF PLASMAS FROM THE TEXTILE VIEWPOINT PRESSURE-BASED SUBSTRATE-BASED PLASMA TREATMENT OF TEXTILE MATERIALS OVERVIEW OF FUNCTIONALIZATIONS EFFECT OF PLASMA TREATMENT ON TEXTILE SUBSTRATES INTERACTION OF ACTIVE PLASMA SPECIES WITH A SURFACE BASIC PLASMA EFFECT ON SUBSTRATE AGING INTEGRATION OF PLASMA PROCESSES INTO THE TEXTILE MANUFACTURING CHAIN FIBER LEVEL FILAMENT LEVEL YARN LEVEL NATURAL MATERIALS COTTON WOOL OTHER NATURAL FIBERS NON-NATURAL MATERIALS FABRIC LEVEL WOVEN TEXTILES KNITTED TEXTILES NON-WOVENS INTERMEDIATE/FINISHED TEXTILE MATERIAL SPECI?C REQUIREMENTS FOR THE TEXTILE INDUSTRY CHEMICAL COMPOSITION SURFACE CLEANLINESS THREE-DIMENSIONAL STRUCTURE OF TEXTILES LARGE SURFACE AREA MOISTURE REGAIN AND AIR ADSORPTION CASE STUDIES ASSESSING THE SURFACE ENERGY OF TEXTILES INTRODUCTION TO METHODS FOR EVALUATING THE SURFACE ENERGY AND WETTING OF TEXTILES WILHELMY METHOD WASHBURN METHOD EVALUATION OF METHODS FOR MEASURING HYDROPHILIC PROPERTIES SUMMARY OF EVALUATION TESTS AND STANDARDS FOR EVALUATING HYDROPHOBIC/OLEOPHOBIC PROPERTIES WATER REPELLENCY: SPRAY TEST WATER/ALCOHOL REPELLENCY OIL REPELLENCY HYDROPHILIC PROPERTIES IMPARTED BY PLASMA PLASMA EXPERIMENTS AT LOW PRESSURE FIRST SCREENING OF PRECURSORS AGING OF THE SAMPLES PLASMA EXPERIMENTS AT ATMOSPHERIC PRESSURE (ALDYNE SYSTEM) HYDROPHOBIC/OLEOPHOBIC PROPERTIES IMPARTED BY PLASMA PRELIMINARY EXPERIMENTS WASHING DURABILITY ABRASION DURABILITY SUMMARY OF OLEOPHOBIC PROPERTIES TRANSFERRING PLASMA TECHNOLOGY TO INDUSTRIAL PROCESSES TEXTILE SECTOR RELATED ISSUES FUNDAMENTAL ASPECTS REGARDING INDUSTRIALIZATION PREVENTING BIO?LM FORMATION ON BIOMEDICAL SURFACES BACTERIAL ADHESION TO BIOMATERIALS: BIO?LM FORMATION ‘BIO?LM’ AND ITS IMPLICATIONS IN THE BIOMEDICAL FIELD MECHANISM FOR BACTERIAL ADHESION TO SURFACES BIO?LM FORMATION – A MULTISTEP PROCESS FACTORS IN?UENCING BIO?LM FORMATION ROLE OF THE CONDITIONING FILM MATERIAL SURFACE CHARACTERISTICS MICRO-ORGANISM CHARACTERISTICS ENVIRONMENTAL FACTORS BIO?LM PREVENTION STRATEGIES PRE-SURGERY PRECAUTIONARY APPROACH ANTIMICROBIAL-RELEASING BIOMATERIALS SURFACE-ENGINEERING APPROACH HIGH SURFACE ENERGY APPROACH LOW SURFACE ENERGY APPROACH SURFACES WITH BOUND TETHERED ANTIMICROBIAL AGENTS ‘ANTIBIO?LM’ APPROACH ROLE OF PLASMA PROCESSING IN BIOFOULING PREVENTION PLASMA SURFACE FUNCTIONALIZATION PLASMA-INDUCED GRAFTING PLASMA STERILIZATION CASE STUDY: PLASMA-DEPOSITED POLY(ETHYLENE OXIDE)-LIKE FILMS FOR THE PREVENTION OF BIO?LM FORMATION PEO FILMS AND PLASMA DEPOSITION PLASMA POLYMERIZATION BY CONTINUOUS WAVE PLASMA RETENTION OF THE PEO CHARACTER AND FILM STABILITY PROTEIN ADSORPTION CELL ATTACHMENT AND PROLIFERATION PLASMA POLYMERIZATION IN PULSED MODE STERILIZATION OF PEO-LIKE FILMS COMPOSITE FILMS: AG NANOPARTICLES IN A PEO-LIKE MATRIX SYNTHESIS OF AG NANOPARTICLES AND DEPOSITION ON SURFACES COMPOSITE AGNP/PEO SURFACES AND THEIR ANTIBACTERIAL ACTIVITY OXYGEN BARRIERS FOR POLYMER FOOD PACKAGING FUNDAMENTALS OF GAS DIFFUSION THROUGH POLYMERS DIFFUSION, SOLUBILITY, AND PERMEABILITY OF POLYMERS DIAGNOSTIC METHODS BARRIER CONCEPTS CASE STUDY: PLASMA DEPOSITION OF SIOX BARRIER FILMS ON POLYMER MATERIALS RELEVANT FOR PACKAGING APPLICATIONS MATERIALS AND MEASUREMENTS SELECTION OF TWO-DIMENSIONAL AND THREE-DIMENSIONAL POLYMER SUBSTRATES MEASUREMENT OF THE STEADY-STATE O2 PARTICLE FLUX MEASUREMENT OF THE COATING THICKNESS SIOX BARRIER FILMS ON PET FOIL SIOX BARRIER FILMS DEPOSITED FROM O2: HMDSO GAS MIXTURES O2 PERMEATION MEASUREMENTS: DETERMINATION OF THE DIFFUSION COEF?CIENT O2 PERMEATION MEASUREMENTS: VARIATION OF THE O2: HMDSO GAS MIXTURE RATIO FTIR ANALYSIS: CHEMICAL COMPOSITION OF THE SURFACE OF THE SIOX BARRIER FILMS DEPOSITED FROM DIFFERENT O2: HMDSO GAS MIXTURES SIOX BARRIER FILMS DEPOSITED FROM O2 : HMDSN GAS MIXTURES O2 PERMEATION MEASUREMENTS: VARIATION OF THE O2: HMDSN GAS MIXTURE RATIO FTIR ANALYSIS: COMPARING BEST PERFORMING SIOX BARRIER FILMS DEPOSITED FROM O2 : HMDSO AND FROM O2 : HMDSN GAS MIXTURES O2 PERMEATION MEASUREMENTS: VARIATION OF THE FILM THICKNESS SIOX BARRIER FILMS ON PP FOIL ECR PLASMA SOURCE: COMPARING THE BARRIER PROPERTIES OF SIOX FILMS DEPOSITED ON PP AND ON PET FOIL BY VARIATION OF THE O2 : HMDSO GAS MIXTURE RATIO DUO-PLASMALINE PLASMA SOURCE: SIOX BARRIER FILMS DEPOSITED FROM O2: HMDSN GAS MIXTURES ECR PLASMA DEPOSITION OF SIOX BARRIER FILMS ON POLYMER TRAYS DESIGNED FOR FOOD PACKAGING ECR PLASMA DEPOSITION OF SIOX BARRIER FILMS WITHOUT DIRECTED GAS SUPPLY AND CUSTOMIZED MAGNET CON?GURATION: VARIATION OF THE PLASMA DEPOSITION TIME AND OF THE DISTANCE BETWEEN SAMPLE AND PLASMA ACHIEVING INDUSTRIALLY RELEVANT PLASMA DEPOSITION TIMES BY DIRECTED GAS SUPPLY AND CUSTOMIZED MAGNET CON?GURATION ACKNOWLEDGMENTS ANTI-WEAR COATINGS FOR FOOD PROCESSING RECENT DEVELOPMENTS IN PVD COATINGS COATINGS TRENDS AND MARKET SHARE COATINGS APPLICATION IN THE FOOD PROCESSING SECTOR COATING REQUIREMENTS IN THE FOOD SECTOR WEAR RESISTANCE COEF?CIENT OF FRICTION (COF) SELECTION OF METHODOLOGIES FOR EFFECTIVE CHARACTERIZATION OF COATINGS FOR THE FOOD SECTOR CHEMICAL AND STRUCTURAL CHARACTERIZATION APPLICATION TO ANTI-WEAR COATINGS FOR FOOD PROCESSING TOOLS ENERGY DISPERSIVE X-RAY SPECTROMETRY (EDX) APPLICATION TO ANTI-WEAR COATINGS CALOTEST AND OPTICAL MICROSCOPY (OM) MECHANICAL CHARACTERIZATION HARDNESS PIN-ON-DISK ATOXICITY AND CORROSION CHARACTERIZATION FOOD COMPATIBILITY: HEAVY METALS RELEASE FOOD COMPATIBILITY: OXIDATION TEST SALT SPRAY TEST CASE STUDIES: DEVELOPMENT AND CHARACTERIZATION OF CERAMIC COATINGS FOR FOOD PROCESSING APPLICATIONS RELEVANT SUBSTRATES AND FUNCTIONALITIES REQUIRED FOR CUTTING APPLICATIONS TECHNICAL ANALYSIS AND CHOICE OF THE PROPER COATING CHEMISTRY AND TECHNIQUE COATING DEVELOPMENT CASE STUDY: PVD COATING OF SAW BLADES CASE STUDY: PVD COATING OF HAMMERS FOR FOOD TREATMENT PHYSICS AND CHEMISTRY OF NONTHERMAL PLASMA AT ATMOSPHERIC PRESSURE RELEVANT TO SURFACE TREATMENT DISCHARGE MODELING FULL KINETIC MODELS AND REDUCED MODEL FOR TECHNOLOGICAL PLASMA ELECTRON KINETICS PLASMA CHEMISTRY EXPERIMENTAL UV, OPTICAL, AND NEAR INFRA-RED EMISSION SPECTRA AIR-BASED DISCHARGES NITROGEN-BASED DISCHARGES CF4-BASED DISCHARGES IN?UENCE OF IMPURITIES ON COMPOSITION OF GAS ACTIVATED BY NONTHERMAL PLASMA KINETIC MODEL FOR CHEMICAL REACTIONS ON A POLYPROPYLENE SURFACE IN ATMOSPHERIC PRESSURE AIR PLASMA DESCRIPTION OF KINETIC MODEL DESCRIPTION OF CHEMICAL REACTION MODELING DESCRIPTION OF SURFACE CONCENTRATION MODELING 10 3 1 2 1 ABSTRACTION OF H ATOMS FROM H-SITES BY OH RADICALS 10 3 1 2 2 ABSTRACTION OF H ATOMS FROM H-SITES BY ALKOXY RADICALS 10 3 1 2 3 CHAIN BACKBONE SCISSION DUE TO INTERACTION OF ALKOXY RADICALS WITH THE POLYMER BACKBONE RESULTS OF MODELING AND COMPARISON WITH EXPERIMENTAL DATA ACKNOWLEDGEMENT PART III ECONOMICAL, ECOLOGICAL, AND SAFETY ASPECTS ECONOMIC ASPECTS MARKET ANALYSIS: AN OVERVIEW TEXTILE MARKET ANALYSIS GENERAL TECHNICAL TEXTILES HYDROPHOBIC AND OLEOPHOBIC TEXTILE MARKET BIOMEDICAL MARKET PERSPECTIVE FOOD PACKAGING MARKET POTENTIAL CASE STUDY: UP-SCALING OF THE PLASMA TREATMENT OF HAMMERS FOR MEAT MILLING ANALYSIS OF THE REFERENCE SCENARIO ANALYSIS OF SCENARIO 2 – OUTSOURCING ANALYSIS OF SCENARIO 3 – IN-HOUSE INVESTMENT AND OPERATING COST COMPARATIVE ANALYSIS OF ALL THREE SCENARIOS FINAL CONSIDERATIONS ENVIRONMENT AND SAFETY INTRODUCTION TO LCA ENVIRONMENTAL IMPACT OF TRADITIONAL SURFACE PROCESSING: THE REASON FOR DEVELOPING INNOVATIVE SOLUTIONS SUPPORTED BY DEDICATED LCA LCA APPLIED TO PLASMA SURFACE PROCESSING: CASE STUDIES SCOPE, FUNCTIONAL UNIT, AND SYSTEM BOUNDARIES LIFE CYCLE INVENTORY (LCI) AND HYPOTHESIS INVENTORY DATA AND RESULTS THE ANTI-CORROSION PROCESS TEXTILE PROCESSES 12 3 3 2 1 TOTAL ENERGY REQUIREMENT 12 3 3 2 2 OUTPUT OF THE OLEOPHOBIC PET PROCESSES 12 3 3 2 3 OUTPUT OF THE HYDROPHOBIC PET/COTTON PROCESSES IMPACT ASSESSMENT SENSITIVITY ANALYSIS MANAGING UNCERTAINTIES EXAMPLE 1: GENERAL SENSITIVITY ANALYSIS FOR THE LCA STUDY OF THE TEXTILE PROCESSES EXAMPLE 2: DESIGN OF PLASMA PROCESSES VIA LCA CONCLUDING CONSIDERATIONS ON LCA STUDY PROCESS SAFETY FOR THE WORKING ENVIRONMENT ATMOSPHERIC PRESSURE PLASMA UNIT: STANDARD CON?GURATION DEVISING SAFE PROCESSES FOR INDUSTRIAL APPLICATIONS MAINTAINING THE SEMI-CONTINUOUS FEEDING FINAL CONSIDERATIONS ON PROCESS SAFETY