Continuous processing of polymers in repetitively pulsed atmospheric pressure discharges with moving surfaces and gas flow

Atmospheric pressure corona discharges are industrially employed to treat large areas of commodity polymer sheets by creating new surface functional groups. The most common processes use oxygen containing discharges to affix oxygen to hydrocarbon polymers, thereby increasing their surface energy and wettability. The process is typically continuous and is carried out in a web configuration with film speeds of tens to hundreds of cm s −1 . The densities and relative abundances of functional groups depend on the gas composition, gas flow rate and residence time of the polymer in the discharge zone which ultimately determine the magnitude and mole fractions of reactive fluxes to the surface. In this paper, results are discussed from a two-dimensional computational investigation of the atmospheric pressure plasma functionalization of a moving polypropylene sheet in repetitively pulsed He/O 2 /H 2 O discharges. O and OH typically initiate surface processing by hydrogen abstraction. These species are regenerated during every plasma pulse but are also largely consumed during the inter-pulse period. Longer-lived species such as O 3 accumulate over many pulses and convect downstream with the gas flow. Optimizing the interplay between local rapid reactions, such as H abstraction which occurs dominantly in the discharge zone, and non-local slower processes, such as surface–surface reactions, may enable the customization of the relative abundance of surface functional groups.