atmospheric pressure plasma a new technology for modifying … · 2013-03-14 · 22. hofer...
TRANSCRIPT
122. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Atmospheric Pressure Plasma
A New Technology for Modifying Technical Textiles
Dr. Birgit Severich
Freudenberg New Technologies KG
22. Hofer Vliesstofftage, 07.-08.11.2007
222. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
We are Part of the Freudenberg Group
Corporate Headquarters:
Freudenberg und Co.
Kommanditgesellschaft
69465 Weinheim
Deutschland
www.freudenberg.de
Employees 2006: 33.526
Turnover 2006: 5.053 Mio €
322. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Parent Company: Freudenberg & Co.
Seals and Vibration
Control Technology
Business Area
Nonwovens
Business Area
Household Products
Business Area
Specialities and Others
Business Area
Business Groups
Seals and Vibration
Control Technology
Europe
1075 Mio €
Seals and Vibration
Control Technology
America
986 Mio €
Seals and Vibration
Control Technology China
96 Mio €
Vibracoustic Europe
451 Mio €
Burgmann Industries
359 Mio €
Business Groups
Nonwovens
801 Mio €
Freudenberg Politex
Nonwovens
216 Mio €
Business groups
Chemical Specialities
470 Mio €
Building Systems
158 Mio €
Mechatronics
14 Mio €
IT-Services
51 Mio €
New Technologies
26 Mio €
Division
Service Support
111 Mio €
Business Group
Household Products
627 Mio €
Organisation of the Freudenberg Group / Turn Over 2006
422. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Freudenberg New Technologies KG (FNT)
Freudenberg Forschungsdienste KG New Business Development
Internal Venturing
• New Business Projects
• Start Ups
- FFCCT
External Venturing
• Fraunhofer VC
• Condias
FNT Corporate Tasks
Management Support EU-, Berlin- Presence/Funding
New Business Ideas Cooperation Japan/USA/China …
Networking with Universities, Associations etc
Organisational Structure of Freudenberg New Technologies
Materials and Processing
Testing and Calculation
Patents and Brands
522. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Introduction
Technical solution
Application examples
Summary
Agenda
622. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Plasma - The 4th Physical State of Matter
solid liquid gaseous plasma
energy energy energy
Plasma is an ionized gas - generated by applying energy to a volume of gas
“Low temperature” plasma
energy is delivered by a high electric field
uniquely combines high chemical reactivity with ambient gas temperature operation
+
+
+
--
----
+
722. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Idea
Establish and commercialize the
plasma technology for roll-goods
in an industrialized, continuous,
non-vacuum process
Customize the surface
characteristics of
nonwovens
technical textiles
polymer films and
membranes
while the bulk properties are left
unaffected by the process
© Dow Corning
822. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
plasma processing
energy efficient
ambient temperature
high chemical
reactivity
environment-
friendly
long-term stable
effects
Atmospheric Pressure Plasma Advantages
Combines atmospheric pressure
plasma processing with liquid
precursors
customized surfaces,
bulk properties
left unaffected
control over
surface functionality
eco-friendly,
continuous processing
atmospheric
pressure
continuous processing
no vacuum equipment
applicable to
temperature and
vacuum sensitive
substrates
liquid precursors
unrivalled control
over plasma coating
chemistry and functionality
wide range of precursors
complex functionality
possible
high deposition rate
922. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Customer Value
Create novel products, or enhance
the performance of existing products
Replace high-priced specialties by
cost-saving modified commodities
Replace polluting wet-chemical
processing
enter new markets,
technology leadership
enhanced market penetration,
increased margins leveraged by
premium products
process cost saving (less
energy, water, waste,
raw materials)
environment, health and safety
benefits
1022. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Agenda
Introduction
Technical solution
Application examples
Summary
1122. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
The Processes
Plasma activation
long-term stable hydrophilization and/or activation as a pretreatment of
polymer and natural substrates prior to coating, dying, lamination and
other adhesion processes
Plasma functionalization
preparation of polymer and natural surfaces for specific reactions
(chemical affinity) by generation of functional chemical groups
Plasma polymerization
sub-micron highly functional layer deposition to get new performance
coatings and finishing
1222. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
The Technical Solution – I
Activation / Hydrophilization
Dielectric Barrier Discharge (DBD)
configuration: rod electrodes, grounded drum
pressure: open perimeter - atmospheric
pressure
process gas: air
temperature: ambient temperature - air cooled
system
substrate: roll-goods - up to 3 mm thickness
pilot line with 1000 mm width
and 5-20 m/min
1322. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
The Technical Solution – II
Functionalization / Coating
Atmospheric Pressure Plasma Liquid
Deposition (APPLD)
configuration: parallel plates, helium
atmosphere
pressure: open perimeter - atmospheric
pressure
temperature: ambient temperature - air cooled
system
chemistry: direct introduction of liquid
precursor (aerosol) into the plasma zone
substrate: roll-goods - up to 3 mm thickness
pilot line with 1000 mm width
and 10-50 m/min
ele
ctr
od
e
ele
ctr
od
e
ele
ctr
od
e
ele
ctr
od
e
nozzle
substrate in substrate
out
1422. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Equipment Platforms
Activation / Hydrophilization Functionalization / Coating
copyright of Dow Corning
© Dow Corning
© Dow Corning
1522. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Agenda
Introduction
Technical solution
Application examples
Summary
1622. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Added Value Products
Applications
special finishing
and coatingsadded value
protective / safety clothing
hospital and health care
automotive components
packaging
buildings / flexible structures
filter media
– oil / stain resistant
– bioactive
– adhesion promotion
– breathable
hydrophobic
– antimicrobial
– hydrophilic
– multi-functional
– release
long-term stable
plasma activation
plasma
functionalization
plasma polymerization
(nano coating)
1722. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Long-term Stable Activation: Battery Separators
Initial wettability
wickng rate after 10 min
Durability in KOH
wicking rate after 30 min
A-Plasma 95-120 mm 40-60 mm
Fluorination 10-20 mm 40-50 mm
In NiMH rechargeable battery separators
made from nonwoven PP or PP/PE are used
Substrate is hydrophobic by nature,
insufficient wetting with water based
electrolytes
Activation / hydrophilization without the need
of any chemistry
excellent initial wettability
long-term stability at ambient condition
shown for more than 18 month
durability after storage
in 30 % KOH (70°C)
hydrophilic
untreated
1822. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Hydrophilic and Reactive Coatings
Features & results
retention of molecular structure in
poly(acrylic acid) coating:
–COOH rich
low water contact angle
Benefits & applications
high surface energy
acid rich & very reactive
water wicking, extra absorbency
anti-fog
easy take-up and good coverage for
printing, coating, dyeing, etc
© Dow Corning
0
20
40
60
80
100
Co
nta
ct A
ng
le (
º)
PP untreated
PAA
PP with APPLD PAA
1922. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Oleophobic / Hydrophobic Coatings
Features & results
retention of molecular structure in
coating: long-chain CFx and cyclic
siloxanes
large tetradecane and water contact
angle
AATCC standard oil rating > 4
laundry durable
Benefits & applications
oil & solvent repellency
excellent stain resistance and
easy-clean performance
water repellent
friction control
low release force
combined with high reusability
Oil droplets on fluorocarbon coated PET nonwoven
2022. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
O O CH2CH
2(CF2)
7CF
3O O CH
2CH
2(CF2)
7CF
3
Oleophobic / Hydrophobic Coatings
Features & results
retention of molecular structure in
coating: long-chain CFx and cyclic
siloxanes
large dodecane and water contact
angle
AATCC standard oil rating > 6
laundry durable
Benefits & applications
oil & solvent repellency
easy clean
water repellent
friction control
low release force
combined with high reusability
298 296 294 292 290 288 286 284 282
C*-COOR
C-C/C-H
C*H2-CF2
COOC
C*F2-CH2/C*F2-CF3
CF3
298 296 294 292 290 288 286 284 282
Binding Energy (eV)
C*-COOR
C-C/C-H
C*H2-CF2
COOC
C*F2-CH2/C*F2-CF3
CF2
CF3
© Dow Corning
2122. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Functionalized Textile Surfaces
-100
-75
-50
-25
0
25
50
75
100
2 3 4 5 6 7 8 9 10
pH (3*10-4
M KCl)
zeta
pote
ntia
l [m
V]
untreatedfunctionalized
-100
-75
-50
-25
0
25
50
75
100
2 3 4 5 6 7 8 9 10
pH (3*10-4
M KCl)
zeta
pote
ntia
l [m
V]
untreatedfunctionalized
Polyester nonwoven with positively
charged surface
basic functional groups, covalently
bonded to the fibre surface
Positive Zeta Potential in aqueous
media up to pH >8
2222. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Agenda
Introduction
Technical solution
Application examples
Summary
2322. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Summary
Enables innovative products and processes
Combines atmospheric pressure plasma processing
with liquid precursors
Delivers highly functional thin-film coatings for large
area flexible substrates
Industrialized continuous process
Surface characteristics can be customized
Bulk properties remain unaffected
Process cost saving and environmental benefits
2422. Hofer Vliesstofftage 08.11.2007 / Birgit Severich
Benefits for our Customers
Unique, customized, high value-added solutions for surface
modifications
product and process development for different customers
pilot production
toll-manufacturing on smaller scale (1m width)
scale-up and transfer to customer’s production
together with our Partner Dow Corning Plasma Solutions
incl. surface analysis expertise
i
d
e
a
feasibili
ty
developm
entcustome
r
sampli
ngtoll-manufacturingpilot process integration