| The purpose of this research was to develop a novel process that would achieve biocidal properties on Kevlar fabric via atmospheric pressure plasma jet (APPJ) induced-graft polymerization of monomers. In the course of the study, experiments were carried out to understand plasma-monomer-substrate interactions, particularly, how each of the main parameters in the plasma processing affects the formation of surface radicals and eventually the degree of graft polymerization of monomers. The study also served to explore the possibility of developing plasma-initiated and plasma-controlled graft polymerization for continuous operation. In this regards, three methods of processing were studied, which included two-step plasma graft-polymerization with immersion, two-step and one-step plasma graft-polymerization with pad-dry.;In general, plasma treatment did not cause visible damage to the surface of Kevlar fibers, except for the appearance of tiny globules distributed almost uniformly indicating a minor effect of plasma treatment to the surface morphology of the polymer. From the examination of SEM images, however, it was found that a very localized surface etching seemed to have taken place, especially at high RF power (800 W) and long time of exposure (60 s), even in plasma downstream mode of operation. It was suggested that a small amount of charged particles might have escaped and reached the substrate surface. High density of surface radicals, which is the prerequisite for high graft density and high antimicrobial activity, was achieved by the combination of high RF power and short exposure time or low RF power and long time of exposure. This was a clear indication that the formation of surface radicals is a function of amount of the dissipated energy, which also explained the two-factor interaction between the two process parameters.;XPS results showed that hydrolysis of the anilide bond of PPTA chains took place to some extent on the surface of Kevlar, leading to the formation carboxylic and phenyl amine groups, which may provide additional active sites for grafting by way of hydrogen abstraction from the latter. Further analysis of XPS data, however, showed that macroradicals and active sites of grafting were formed at least at one of the carbon atoms in the aromatic ring.;A reduction of microbial activity up to 3-log reduction was achieved by plasma treated Kevlar grafted by either diallyl diammonium chloride (DADMAC) or 3- ((trimethoxysilyl)-propyl) dimethylammonium chloride (TMS), with the latter being the one with better performance. It was found that high antimicrobial activity was obtained by the combination of high RF power, short time of exposure, and low concentration of monomer. Of the three processing methods studied, the one with immersion method produced higher graft yield. However, one-step plasma graft-polymerization with pad-dry method has proven itself more interesting due to its potential for an open continuous process.;This research has been successful in producing effective antimicrobial properties on Kevlar fabric by plasma-initiated and plasma-controlled graft polymerization, which is unprecedented. The design of experiments showed that better results with higher order of log reduction can be obtained by process optimization, e.g. by using response surface methods. It would also be very beneficial to continue the research for the development of plasma graft-polymerization process with more rigorous design, which involves the use of crosslinker and antimicrobial monomers with different chemistry. A study that involves the development of a robust design for processes that perform consistently as intended under a wide range of user's conditions and yet produce high-level performance with high reliability would also be advantageous.;The major implication of the findings from this research for the finishing of Kevlar is that a wide array of different surface functionalities may become more readily available now than ever. Plasma technology has made surface chemistry functionalization of Kevlar more straightforward and easier to perform, which opens new avenues for achieving functional and multifunctional Kevlar fabrics using a fast, more economic and environmentally friendly continuous process for niche market such as military applications and protective clothing for emergency responders. |
