This paper describes theoretical and experimental investigations of the effect of an electrode coating on the onset voltage of a corona on negatively stressed electrodes. Dielectric-coated hemispherically-capped rod-to-plane gaps positioned in air are investigated. The onset voltage is calculated based on the self-recurring single electron avalanche developed in the investigated gap. Accurate calculation of the electric field in the vicinity of a coated rod and its correlation to the field values near a bare rod of the same radius are obtained using the charge simulation method. The calculated field values are utilized in evaluating the onset voltage of the corona. Also, laboratory measurements of the onset voltage on bare and coated electrodes are carried out. The effects of varying the field nonuniformity, the coating thickness and its permittivity on the onset voltage values are investigated. The results show that coating the electrodes with a dielectric material is effective in increasing the onset voltage of the corona on its surface. The calculated onset voltage values for coated and bare electrodes agree satisfactorily with those measured experimentally.

Interest has grown over the past few years in applying atmospheric pressure plasmas to plasma processing for the benefits this can offer to existing and potential new processes, because they do not require expensive vacuum systems and batch processing. There have been considerable efforts to efficiently generate large volumes of homogeneous atmospheric pressure non-thermal plasmas to develop environmentally friendly alternatives for surface treatment, thin film coating, sterilization, decontamination, etc.

Many interesting questions have arisen that are related to both fundamental and applied research in this field. Many concern the generation of a large volume discharge which remains stable and uniform at atmospheric pressure. At this pressure, depending on the experimental conditions, either streamer or Townsend breakdown may occur. They respectively lead to micro-discharges or to one large radius discharge, Townsend or glow. However, the complexity arises from the formation of large radius streamers due to avalanche coupling and from the constriction of the glow discharge due to too low a current. Another difficulty is to visually distinguish many micro-discharges from one large radius discharge. Other questions relate to key chemical reactions in the plasma and at the surface. Experimental characterization and modelling also need to be developed to answer these questions.

This cluster collects up-to-date research results related to the understanding of different discharges working at atmospheric pressure and the application to polymer surface activation and thin film coating. It presents different solutions for generating and sustaining diffuse discharges at atmospheric pressure. DC, low-frequency and radio-frequency excitations are considered in noble gases, nitrogen or air. Two specific methods developed to understand the transition from Townsend to streamer breakdown are also presented. They are based on the cross-correlation spectroscopy and an electrical model.

In this paper, we present data on the physics and phenomenology of plasma reactors based on the One Atmosphere Uniform Glow Discharge Plasma (OAUGDP^™) that are useful in optimizing the conditions for plasma formation, uniformity and surface treatment applications. It is shown that the real (as opposed to reactive) power delivered to a reactor is divided between dielectric heating of the insulating material and power delivered to the plasma available for ionization and active species production. A relationship is given for the dielectric heating power input as a function of the frequency and voltage at which the OAUGDP^™ discharge is operated.

The surface tension of a model, water-based, flexographic printing ink was measured at a range of surfactant concentrations along with the equilibrium contact angle formed with polymer substrates. The surface excess of surfactant at each concentration was calculated using the Gibbs adsorption isotherm and assumed equal to the concentration of surfactant at the interface. The change in the surface tension of the ink formulation was assumed to be determined entirely by the surface concentration of surfactant. This allowed the estimation of the surface tension at the solid–liquid and solid–vapour boundaries when in contact with substrate based on the values obtained for pendant drops. The associated polar and dispersive contributions to the surface tension were then calculated using the Young–Dupré equation. The values of the polar and dispersive surface tension components extracted in this manner were compared with those calculated using the approach of van Oss, Chaudhury and Good. The use of surface excess in estimating the contributions to surface tension was found to give far better agreement with experimental data than the van Oss approach which is intended for use with pure liquids.

There has been considerable interest in non-thermal atmospheric pressure discharges over the past decade due to the increased number of industrial applications. Diverse applications demand a solid physical and chemical understanding of the operational principals of such discharges. This paper focuses on the four most important and widely used varieties of non-thermal discharges: corona, dielectric barrier, gliding arc and spark discharge. The physics of these discharges is closely related to the breakdown phenomena. The main players in electrical breakdown of gases: avalanches and streamers are also discussed in this paper. Although non-thermal atmospheric pressure discharges have been intensively studied for the past century, a clear physical picture of these discharges is yet to be obtained.

A study on oxygen-plasma treatment of ink-jet paper is presented. Paper was exposed to a weakly ionized, highly dissociated oxygen plasma with an electron temperature of 5 eV, a positive-ion density of 8 × 10¹⁵ m⁻³ and a density of neutral oxygen atoms of 5 × 10²¹ m⁻³. Optical emission spectroscopy (OES) was applied as a method for detection of the reaction products during the plasma treatment of the paper. OES spectra between 250 and 1000 nm were measured continuously during the plasma treatment. The wettability of the samples before and after the plasma treatment was determined by measuring the contact angle of a water drop. The appearance of the surface-functional groups was determined by using high-resolution x-ray photoelectron spectroscopy (XPS), while changes in the surface morphology were monitored with scanning electron microscopy (SEM). Already after 1 s of the plasma treatment the surface, which was originally hydrophobic, changed to hydrophilic, as indicated by a high absorption rate of a water drop into the paper. The OES showed a rapid increase of the CO and OH bands for the first few seconds of the plasma treatment, followed by a slow decrease during the next 40 s. The intensity of the O atom line showed reversed behaviour. The XPS analyses showed a gradual increase of oxygen-rich functional groups on the surface, while SEM analyses did not show significant modification of the morphology during the first 10 s of the plasma treatment. The results were explained by degradation of the alkyl ketene dimer sizing agent during the first few seconds of the oxygen-plasma treatment.

Plasma polymer surface modification is widely used in the biomedical field to tailor the surface properties of materials to improve their biocompatibility. Most of these treatments are performed using low pressure plasma systems but recently, filamentary dielectric barrier discharge (FDBD) and atmospheric pressure glow discharge (APGD) have appeared as interesting alternatives. The aim of this paper is to evaluate the potential of surface modifications realized with FDBD and APGD in different atmospheres (N₂+ H₂ and N₂+ NH₃ mixtures) on poly(tetrafluoroethylene) to determine the relative influence of both the discharge regime and the gas nature on the surface transformations. From XPS analysis, it is shown that the discharge regime can have a significant effect on the surface transformation; FDBDs operating in H₂/N₂ lead to a high concentration of amino-groups with high specificity but also important damaging on the surface. Glow discharges in both H₂/N₂ and NH₃/N₂ lead to lower concentrations of amino-groups with lower specificity but lower surface damaging. Therefore, this simple surface treatment seems to be an effective, low cost method for the production of uniform surface modification with amino-groups that can subsequently be used to graft various chemical functionalities used for biomaterial compatibility.

An atmospheric pressure glow discharge (APGD) was used for surface modification of polyethylene (PE) and polypropylene (PP). The discharge was generated between two planar metal electrodes, with the top electrode covered by a glass and the bottom electrode covered by the treated polymer sample. The discharge burned in pure nitrogen or in nitrogen-hydrogen or nitrogen-ammonia mixtures. The surface properties of both treated and untreated polymers were characterized by scanning electron microscopy, atomic force microscopy, surface free energy measurements and x-ray photoelectron spectroscopy. The influence of treatment time and power input to the discharge on the surface properties of the polymers was studied. The ageing of the treated samples was investigated as well. The surface of polymers treated in an APGD was homogeneous and it had less roughness in comparison with polymer surfaces treated in a filamentary discharge. The surface free energy of treated PE obtained under optimum conditions was 54 mJ m^-2 and the corresponding contact angle of water was 40° the surface free energy of treated PP obtained under optimum conditions was 53 mJ m^-2 and the contact angle of water 42°. The maximum decrease in the surface free energy during the ageing was about 10%.

A remote atmospheric pressure discharge working with ambient air is used for the near room temperature treatment of polymer foils and textiles of varying thickness. The envisaged plasma effect is an increase in the surface energy of the treated material, leading, e.g., to a better wettability or adhesion. Changes in wettability are examined by measuring the contact angle or the liquid absorptive capacity. Two regimes of the remote atmospheric pressure discharge are investigated: the glow regime and the streamer regime. These regimes differ mainly in power density and in the details of the electrode design. The results show that this kind of discharge makes up a convenient non-thermal plasma source to be integrated into a treatment installation working at atmospheric pressure.

Polyethylene (PE) is often used in several industrial applications including the building, packaging and transport industries. Aluminum (Al) is widely used in different applications in the automotive, railway, aeronautic, and naval industries because of its excellent mechanical and chemical properties. Laminates prepared from Al and PE lead to an enhancement in physical and mechanical properties. These materials play a main role in the packaging and building sectors, such as in TetraPak containers and aluminum composite panels. The main problem observed is associated with the adhesion between polymers and metals. This research focused on investigating the enhancement in the adhesion of the PE/Al laminate using the corona discharge. The corona treatment of the surfaces led to a significant increase in the adhesion of the PE/Al laminate as a result of improved surface properties confirmed by peel test measurements. Moreover, the positive effect of the corona treatment in combination with a primer on the improvement of adhesion characteristics was observed too. Different analytical techniques were employed to characterize the effect of the corona treatment on the improvement in adhesion of PE/Al. A significant increase in wettability was confirmed by the measurement of contact angles. Changes in the surface morphology of the PE and Al surface, after the corona treatments at different operating conditions, were observed using atomic force microscopy (AFM) and scanning electron microscopy (SEM). In addition, x-ray photoelectron spectroscopy (XPS) and Fourier transform infrared spectroscopy (FTIR) were used to analyze changes in chemical composition after the corona discharge effect on PE and Al surfaces.

It is well known that in extrusion coating, the coating adhesion to the substrate decreases with decreasing thickness. The study on this phenomenon is divided into three parts. Part I explores the reduction in adhesion of LDPE to paper and other porous substrates. Several hypotheses are proposed for the origin of this decrease, including a reduction in oxidation time, faster cooling in the air gap, and more rapid quenching in the nip. A model of the molten polymer penetration into the substrate shows that the greatest effect is cooling in the nip; thinner coatings have less time to flow into the substrate interstices once the chill roll contact is made. The model results agree well with experimental adhesion data from the literature.

In Part II, adhesion to aluminum foil and other nonporous substrates is studied. Several hypotheses are proposed for why peel strength decreases in these structures, including a reduction in the air gap time, faster air gap cooling, more rapid nip quenching, and stress imposed during drawing. Modeling and experimental results show that cooling in the nip and imposed stress have the greatest impact.

In Part III, the peel test is analyzed to understand why the peel strength of better adhering adhesives are more sensitive to changes in coating thickness. The analysis shows that changes in the critical dimension of the deformation region at the peel front may be responsible.

This study describes experiments to quantify polymer surface energy changes after exposure to atmospheric plasma. Atmospheric plasma treatment permits surface functionalization at near-ambient temperatures. Polyethylene and polystyrene are treated with an atmospheric plasma unit. The increased surface energy and improved wetting characteristics lead to a significant adhesion improvement with adhesives that cannot be used without surface treatment.

Polyamide 6, polyamide 12, polybutyleneterephthalate, and polyetherimide films are plasma treated in an APGD unit using various applied voltages, gas flow rates, frequencies, and dwell times. The results show changes in the surface chemistry (FTIR); the degree of change in dynamic contact angle is found to be dependent on the polymer type, dwell time, and electrical characteristics of the plasma.

Blown film processors, large and small, have limited resources in both capital and manpower to devote to optimizing their productivity. Yet avenues of improvement are open for even the most over-extended organization. And some of the most effective modifications cost little more than a small change in equipment orientation or procedures. A key aspect of optimizing a blown film layout is line footprint and determining how to minimize footprint and maximize output with each integral piece of equipment on the line. Multiple surface treatment systems are integral to every blown film line and can control product quality and line efficiencies. The objective of this work is to present best practices of blown film manufacturers ranging from multinationals to small privately owned operations relative to the most effective surface treatment system designs, their roll coverings, optimum power density settings, alternative treatment technologies, troubleshooting protocols, and model line layouts that optimize production output.

The peel characteristics of sealed low-density polyethylene/isotactic polybutene-1 (PE-LD/iPB-1) films, with different contents of iPB-1 up to 20 m.-% (mass percentage), were evaluated and simulated in dependence on the iPB-1 content, and in dependence on the peel rate. Sealing involves close contact and localized melting of two films for a few seconds. The required force, to separate the local adhered films, is the peel force, which is influenced, among others, by the content of iPB-1. The peel force decreases exponentially with increasing iPB-1 content. Transmission electron microscopy studies reveal a favorable dispersion of the iPB-1 particles within the seal area, for iPB-1 concentrations ≥6 m.-%. Here, the iPB-1 particles form continuous belt-like structures, which lead to a stable and reproducible peel process. The investigation of the peel rate-dependency on the peel characteristics is of important interest for practical applications. The peel force increases with increasing peel rate by an exponential law. A numerical simulation of the present material system proves to be useful to comprehend the peel process, and to understand the peel behavior in further detail. Peel tests of different peel samples were simulated, using a two-dimensional finite element model, including cohesive zone elements. The established finite element model of the peel process was used to simulate the influence of the modulus of elasticity on the peel behavior. The peel force is independent of the modulus of elasticity, however, the peel initiation value increases with increasing modulus of elasticity. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2009 https://onlinelibrary.wiley.com/doi/10.1002/app.28999