Characterization and optimization of an atmospheric plasma deposition system for in-line glass fibers treatment

Atmospheric pressure plasma depositions processes are becoming widely implemented in in-line, large-scale industrial application. In the present study, thin films coatings have been deposited by a non-equilibrium atmospheric pressure plasma jet operating on air and organosilane precursors, with the aim of an in-line integration in the industrial production of glass fibers. The characterization of the plasma source, of the resulting thin films, and of the exhaust gases has been carried out over a wide range of operating parameters. Results show a complex dependence on the experimental parameters, including the torch-substrate distance, the plasma operating parameters and the precursor injection management. Cold gas numerical simulations of the plasma jet in an open-air configuration and inside a reactor chamber for industrial production have been carried out and successfully benchmarked with the experimental counterparts. Conclusion drawn from them allowed for a strong reduction in number of necessary plasma torches, while at the same time maintaining a homogeneous coverage of the glass fibers. A second iteration of the reactor chamber, with a halved volume and a better management of the exhaust gas, was made possible on the basis of said simulations, showing promising possibilities for the incorporation into an in-line industrial setup for the high-speed treatment of glass fibers, and consequent improvements in the resulting fibers' surface properties. • Optimized atmospheric plasma jet torch setup for in-line glass fibers treatment • First-time GC–MS detailed analysis of exhaust gas byproducts of APECVD processes • Optimization of overall process and fibers coverage via numerical simulations • Compact reactor chamber design to be integrated seamlessly into industrial setups