Treatment of fibrous materials using atmospheric pressure plasma polymerization

摘要

An apparatus and method for plasma finishing of fibrous materials including paper and knitted, woven and non-woven fibrous substrates such that desired characteristics are imparted are described. The method includes depositing a monomer comprising at least one fluorocarbon monomer with chemical additives, as required, at atmospheric pressure onto the paper or knitted, woven or non-woven substrate; exposing the monomer on a single surface of the fibrous material to an inert gas, atmospheric-pressure plasma, thereby causing polymerization of the monomer species; and repeating this sequence using multiple sequential deposition and plasma discharge steps to create a layered surface having durability against abrasion for both water-based laundry methods and dry-cleaning methods, and normal wear, without affecting the feel, drape, appearance or breathability of the substrate material. The present method uses a high-power, continuously operating plasma that is 104 times more powerful than the prior art plasma sources utilized in the textile industry, and produces a durable finish with between 0.5 and 2 s of plasma exposure. This is sufficiently rapid to meet commercial fabric processing throughput, and repeated cleaning of the electrodes is not required.

主权项

1. A method for continuously treating a substrate with a finish having a chosen characteristic, comprising the steps of:
coating the surface of said substrate by vapor condensation at atmospheric pressure with at least one monomeric precursor of a polymer having said chosen characteristic in a first chamber; moving the coated substrate into a second chamber away from the first chamber; generating an inert gas atmospheric pressure plasma in the second chamber in a volume between an rf electrode and a grounded electrode parallel thereto, wherein the inert gas emanates from either of the rf electrode or the grounded electrode into the volume; applying sufficient rf power to the rf electrode such that an electron-deficient sheath region is generated in the vicinity of each electrode, the coated substrate being disposed within the sheath region of one of either the rf electrode or the grounded electrode; and exposing the coated substrate to the products generated by the plasma in the second chamber, whereby the at least one monomeric precursor is polymerized, thereby forming said finish having said chosen characteristic.