annick vanhulsel, vito sim user forum 19.11...nov 26, 2014 · enhancing the compatibility of...
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Enhancing the compatibility of materials by atmospheric plasma technology
Annick Vanhulsel, VITO SIM User Forum 19.11.2014
SIM User Forum 19/11/2014 2 © 2014, VITO NV
VITO, VIsion on TechnOlogy » Independent research and consultancy centre in the areas of cleantech and
sustainable development; » Bridge between academia – government – industry » Support sustainable technological development in Flanders/Europe/worldwide
Energy Environment Industrial Innovation
SIM User Forum 19/11/2014 3 © 2014, VITO NV
Plasma technology - a powerful tool for surface modification
SUBSTRATE
fragmentation polymerisation
deposition
recombination
SIM User Forum 19/11/2014 4 © 2014, VITO NV
OH NH COOH F C=O
cleaning
functionalisation
nano-coating
Surface modification by atmospheric plasma technology
Plastic, metal, glass, ceramic,…
SIM User Forum 19/11/2014 5 © 2014, VITO NV
Atmospheric Plasma Technology @ VITO
» Cold atmospheric plasma using Dielectric Barrier Discharge (DBD) technology
» Unique combination of gas discharge and addition of chemical precursors
» To obtain a dedicated chemical surface functionalization of many types of materials
» Different plasma configurations for treatment of various substrate types:
» Foils, paper, fibres, non-wovens, plates, 3D components, powders
» Plasma systems from lab-scale to pilot-scale
SIM User Forum 19/11/2014 6 © 2014, VITO NV
Atmospheric plasma technology - USP
» Multiple purpose technology: activation - functionalisation - nanocoating
» Wide variety of chemistry » Cold plasma enabling treatment of temperature sensitive materials » Operates at ambient pressure integration in continuous production
lines » Flexible switching between process conditions » Sustainable technology
Less chemicals to be used Less energy Low emissions
SIM User Forum 19/11/2014 7 © 2014, VITO NV
PlasmaZone® PlasmaSpot® PlasmaLine®
Foils, fibres, membranes etc. 3D parts Foams, plates, non-wovens etc
Confidential
Atmospheric plasma equipment
SIM User Forum 19/11/2014 8 © 2014, VITO NV
Indirect PlasmaSpot® Functionalisation and coating of 3D components
PlasmaLine® Functionalisation of thick substrates
Indirect
Direct PlasmaZone® Functionalisation and coating of thin flat substrates
Different plasma configurations
SIM User Forum 19/11/2014 9 © 2014, VITO NV
» Continuous surface treatment of foils, sheets, yarns integration in industrial production processes
» Pilot-scale roll-to-roll systems @ VITO » Combination of atmospheric plasma treatment and in-line coating or lamination
Scalability of atmospheric plasma technology
Micro roller 1-2 µm Knife coating
50-500 µm
SIM User Forum 19/11/2014 10 © 2014, VITO NV
Scalability of atmospheric plasma technology
SIM User Forum 19/11/2014 11 © 2014, VITO NV
Applications using atmospheric plasma technology
» Surface functionalization for adhesion improvement in sandwich structures
» Surface modification of fine particles to tune the interaction with their environment
» Treatment of carbon fibres to optimize interfacial strength in CFRP
SIM User Forum 19/11/2014 12 © 2014, VITO NV
Adhesion improvement in composite panels
» Adhesion between backside coated steel plates and PE film » PlasmaLine® treatment of polyester coated steel before lamination
to a PE core (PE/PP adhesive film was used)
PE core
Plasma coating Backside coated steel
Adhesive PE film
SIM User Forum 19/11/2014 13 © 2014, VITO NV
Lightweight polymer-steel hybrids
» Studied within SIM NANOFORCE program » Adhesion between stainless steel and epoxy or PA6 resin » PlasmaZone® treatment with a siloxane precursor on stainless steel strongly
improves the adhesion strength » A post condensation (thermal or plasma) was needed to obtain good adhesion
Direct plasma treatment (PlasmaZone®)
SIM User Forum 19/11/2014 14 © 2014, VITO NV
Applications using atmospheric plasma technology
» Surface functionalization for adhesion improvement in sandwich structures
» Surface modification of fine particles to tune the interaction with their environment
» Treatment of carbon fibres to optimize interfacial strength in CFRP
SIM User Forum 19/11/2014 15 © 2014, VITO NV
Control interaction between particle and environment » affinity with matrix material » control level of agglomeration » stability of dispersions
Add extra functionalities to the particle » protective coatings » improved flowability » improved adhesion » …
without changing the bulk material
customized micro/nanopowders with higher added-value
Why?
additives, pigments, composites, cosmetics, catalysis, batteries, biomedical
Plasma functionalisation of micro/nano powders
SIM User Forum 19/11/2014 16 © 2014, VITO NV
SIM horizontal program TRAP Tools for Rational Processing of nanoparticle based materials
» SBO project FUNC- “Tools for dry nanofunctionalization of particles and fibrous materials”
» 1/9/2014 – 31/8/2018
» Development of two complementary technologies for nanofunctionalization of particles: atmospheric plasma and atomic layer deposition (ALD)
» Initial focus on polymer particles, steel fibres and porous particles
» Characterisation of surface modified particles and fibres
SIM User Forum 19/11/2014 17 © 2014, VITO NV
» Powder downflow reactor
» Cold atmospheric plasma – cylindrical configuration
» Dry injection of powder in a gas flow
» Limited residence time of particles in plasma (ms)
» Current powder volumes: 100g à 1 kg/h
» Micro- and nanopowders
» Possibility to add liquid precursors to apply specific functionalities
Atmospheric plasma system for powder treatment
SIM User Forum 19/11/2014 18 © 2014, VITO NV
Atmospheric plasma system for powder treatment
SIM User Forum 19/11/2014 19 © 2014, VITO NV
Improving the dispersion behaviour of powders
After 1h After 24h
PE Untreated
PE N2-treated
CB Untreated
CB N2-treated
CB Untreated
CB N2-treated
2 months after plasma treatment
» Atmospheric plasma functionalisation of PE and carbon black
» Positive effect on the wettability of the particles
» Dispersion test in water Improvement of dispersion stability
SIM User Forum 19/11/2014 20 © 2014, VITO NV
at% O
at% N
Plasma functionalisation of UHMW PE powder
» Plasma functionalisation of UHMW PE particles » Grafting of polar groups at particle surface » Improved dispersion stability of the polymer powder in water
SIM User Forum 19/11/2014 21 © 2014, VITO NV
Atmospheric plasma coating on powders
ZrO2 ZrO2
» Siloxane coating on ZrO2 beads » Several coating patches on particle surface » Coating thickness 10-20 nm
SIM User Forum 19/11/2014 22 © 2014, VITO NV
Applications using atmospheric plasma technology
» Surface functionalization for adhesion improvement in sandwich structures
» Surface modification of fine particles to tune the interaction with their environment
» Treatment of carbon fibres to optimize interfacial strength in CFRP
SIM User Forum 19/11/2014 23 © 2014, VITO NV
NEWSPEC
» NEW cost-effective and Sustainable PolyEthylene based Carbon fibres for volume market applications
» Large-scale integrating EC-project
SIM User Forum 19/11/2014 24 © 2014, VITO NV
Plasma functionalisation of reinforcing fibres
» Change the surface properties (chemical/physical) of the CF (without damaging the fibre structure)
» Create reactive groups/bonding sites on the fibre surface
» Promote adhesion between fibres and matrix key element for optimal mechanical properties of resulting composite material
SIM User Forum 19/11/2014 25 © 2014, VITO NV
Atmospheric plasma treatment of carbon fibres » Develop alternative process for electrochemical oxidation » Flexibility to apply specific functional groups to the fibre surface (not only
oxidation) to match with different matrix materials » Development of a continuous atmospheric plasma process for controlled
oxidation
Courtesy of Amit Naskar
SIM User Forum 19/11/2014 26 © 2014, VITO NV
Conclusion
» Atmospheric plasma technology is a versatile tool for interface engineering
» Can be used to optimize the affinity between different materials in hybrid systems
» Different DBD plasma systems are available for treatment of foils, plates, fibres, particles
» Technology is upscalable for use in roll-to-roll processes » Developments ongoing in 2 SIM programs
www.vitoplasma.com