US20070163499A1 - Plasma treatment apparatus and method - Google Patents
Plasma treatment apparatus and method Download PDFInfo
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- US20070163499A1 US20070163499A1 US10/555,542 US55554204A US2007163499A1 US 20070163499 A1 US20070163499 A1 US 20070163499A1 US 55554204 A US55554204 A US 55554204A US 2007163499 A1 US2007163499 A1 US 2007163499A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J19/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
- B01J19/087—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy
- B01J19/088—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M10/00—Physical treatment of fibres, threads, yarns, fabrics, or fibrous goods made from such materials, e.g. ultrasonic, corona discharge, irradiation, electric currents, or magnetic fields; Physical treatment combined with treatment with chemical compounds or elements
- D06M10/02—Physical treatment of fibres, threads, yarns, fabrics, or fibrous goods made from such materials, e.g. ultrasonic, corona discharge, irradiation, electric currents, or magnetic fields; Physical treatment combined with treatment with chemical compounds or elements ultrasonic or sonic; Corona discharge
- D06M10/025—Corona discharge or low temperature plasma
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
- H05H1/00—Generating plasma; Handling plasma
- H05H1/24—Generating plasma
- H05H1/2406—Generating plasma using dielectric barrier discharges, i.e. with a dielectric interposed between the electrodes
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
- H05H1/00—Generating plasma; Handling plasma
- H05H1/24—Generating plasma
- H05H1/2406—Generating plasma using dielectric barrier discharges, i.e. with a dielectric interposed between the electrodes
- H05H1/2431—Generating plasma using dielectric barrier discharges, i.e. with a dielectric interposed between the electrodes using cylindrical electrodes, e.g. rotary drums
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
- B01J2219/0803—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy
- B01J2219/0805—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges
- B01J2219/0807—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges involving electrodes
- B01J2219/0809—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges involving electrodes employing two or more electrodes
- B01J2219/0813—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges involving electrodes employing two or more electrodes employing four electrodes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
- B01J2219/0803—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy
- B01J2219/0805—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges
- B01J2219/0807—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges involving electrodes
- B01J2219/0815—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges involving electrodes involving stationary electrodes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
- B01J2219/0803—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy
- B01J2219/0805—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges
- B01J2219/0807—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges involving electrodes
- B01J2219/0816—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges involving electrodes involving moving electrodes
- B01J2219/0818—Rotating electrodes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
- B01J2219/0803—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy
- B01J2219/0805—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges
- B01J2219/0807—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges involving electrodes
- B01J2219/0824—Details relating to the shape of the electrodes
- B01J2219/0826—Details relating to the shape of the electrodes essentially linear
- B01J2219/083—Details relating to the shape of the electrodes essentially linear cylindrical
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
- B01J2219/0803—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy
- B01J2219/0805—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges
- B01J2219/0807—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor employing electric or magnetic energy giving rise to electric discharges involving electrodes
- B01J2219/0824—Details relating to the shape of the electrodes
- B01J2219/0832—Details relating to the shape of the electrodes essentially toroidal
- B01J2219/0833—Details relating to the shape of the electrodes essentially toroidal forming part of a full circle
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
- B01J2219/0873—Materials to be treated
- B01J2219/0879—Solid
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/08—Processes employing the direct application of electric or wave energy, or particle radiation; Apparatus therefor
- B01J2219/0894—Processes carried out in the presence of a plasma
- B01J2219/0898—Hot plasma
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
- D06M2101/02—Natural fibres, other than mineral fibres
- D06M2101/10—Animal fibres
- D06M2101/12—Keratin fibres or silk
Definitions
- This invention relates to a method and apparatus for the plasma treatment of gas permeable materials, for instance, fibrous materials.
- the invention is particularly useful when applied to wool.
- Plasma treatment of materials is widely used to alter the surface characteristics of the material.
- the treatment is generally useful where it is uniformly distributed over the surface of the material.
- plasma treatments are used to oxidize a lipid layer on the surface of the fibres. Oxidation of the lipid layer makes the wool fibres more receptive to subsequent surface treatments, for instance anti-shrink and pilling-prevention treatments.
- Removal of the lipid layer also increases friction between the fibres.
- This benefits yam production processes as less twisting is required to form the yam.
- the lower twisting level enables the yarn to be produced at a greater rate, enabling downstream processes to be run faster and thereby increasing output.
- yams having a lower twist exhibit a softer feel relative to higher twist yams and may be used advantageously to produce commercially desirable softer garments in contrast to garments made from high twist yam.
- Plasma treatment of wool and other fibrous materials should provide an even surface treatment to ensure that the material is receptive to downstream processing in a production line. If the surface of the material is not treated evenly, the downstream processes will not have their designed effect and an inferior product will result.
- Another aspect of plasma treatment is that wool and other fibrous materials are susceptible to being locally burnt during the plasma treatment. Again, in a production line, this is highly undesirable where a continuous supply of material is required. Hence, an optimum plasma treatment should minimise the incidence of localised burning of the material being treated.
- Some of the present techniques for the generation of plasma for treating materials involves the adjustment of the applied voltage and its frequency in order to obtain a stable uniform plasma.
- Such plasma is usually generated with gas pressures above or below atmospheric pressure.
- More recently, advances in plasma treatments at atmospheric pressure have involved the use of expensive noble gases to stabilise the plasma in a uniform glow suitable for surface treating materials.
- the cost of plasma treatments above or below atmospheric pressure or involving noble gases makes them less economically viable. Accordingly, interest has been focussed on plasma treatments in air and at atmospheric pressure.
- Roth et al in U.S. Pat. No. 5,403,453, teaches that a uniform glow discharge plasma is created at one atmosphere where ions, produced by the electrical breakdown of helium and/or air, are trapped between the electrodes. Roth indicates that the ion trapping increases the lifetime of the ions in the plasma and thereby results in a lower electrical breakdown threshold and a uniform glow discharge.
- a similar theory is posited in U.S. Pat. No. 6,299,948 to Gherardi et al assigned to L'Air Liquide. According to Roth et al., such trapping is enabled by applying an electrical field alternating at radio frequencies between spaced electrodes. Roth et al. propose a relationship between electrode spacing, electrode voltage and applied frequency that results in ion trapping.
- U.S. Pat. 5,895,558 describes a plasma treatment station for polymer strip at about atmospheric pressure, but preferably slightly superatmospheric pressure, in which gas is blown from an array of holes in one of a pair of closed-spaced planar electrodes. Turbulent high flow gas delivery is employed to delay and disrupt the formation of a filamentary discharge.
- a normal dielectric barrier discharge plasma consists of multiple micro-discharges each of a few nanoseconds duration.
- the plasma is driven by an alternating high voltage applied between the electrodes. Each half-cycle of alternating voltage plasma is generated through a burst of microdischarges.
- the ions from each microdischarge do not normally disperse easily and, having lower electrical resistance compared to the surrounding gas, cause the microdischarges to occur repeatedly at the same locations. This provides very poor uniformity of treatment and fails to use all of the available gas for generation of useful chemical species by the plasma.
- microdischarges increases the probability of generation of a high temperature instability within the plasma that burns the material to be treated. This seems to occur due to the local release by the plasma of particular chemicals from the material surface, possibly where a high concentration of contaminant occurs. The generation of these chemicals changes the nature of the plasma and causes localised excessive absorption of plasma energy and a rapid rise in temperature. Localisation of the microdischarges is believed to result in two effects. Firstly, ions remaining stationary relative to the electrodes cause localisation of the plasma microdischarges between the electrodes and result in uneven and less effective surface treatment. Secondly, trapping of ions and plasma-material by-products in a gas permeable material moving relative to the electrodes causes localisation of the plasma relative to the material and can result in burning of the material.
- the invention therefore, uses a strong gas flow through the gas permeable material to prevent the formation of localised plasma microdischarges by dispersing and/or removing ions and undesirable chemicals during and between alternating voltage cycles from between the electrodes or from within the gas permeable material.
- the invention provides uniform and effective plasma treatment at voltages, frequencies and electrode separations outside the parameters dictated by Roth's theory. Rather than generating a uniform glow discharge as claimed by Roth and others the present invention provides an effective uniform plasma surface treatment using a filamentary but randomised dielectric barrier discharge plasma and without burning the material to be treated.
- the invention provides, in a first aspect, a method of producing a plasma treated gas permeable material, including the steps of:
- a gas permeable material treated by this method has better uniformity of surface characteristics and is less likely to be burned by localized plasma microdischarges.
- the gas moves in a direction transverse to the direction of passage of the gas permeable material between the spaced electrodes.
- the method is facilitated by the step of applying, between the electrodes, a voltage that alternates at a frequency to enable the dispersion and/or removal, in the moving gas, of plasma by-products which cause localisation of the plasma microdischarges.
- a voltage that alternates at a frequency to enable the dispersion and/or removal, in the moving gas, of plasma by-products which cause localisation of the plasma microdischarges.
- Any frequency may be employed, but the frequency may typically be in the range of 1-20 kHz, and is preferably in the range of 1-5 kHz.
- the moving gas not only removes ions, but also noxious plasma by-products, such as O3 and NO2.
- the gas used in the method may be any gas suitable for electrical breakdown to generate a plasma, such as noble gas or a gas inert to the material, but is preferably air.
- the gas used in the method may have a gas pressure above or below atmospheric pressure.
- the gas pressure is atmospheric pressure.
- the voltage applied to the spaced electrodes is typically in the range 10-25 kV.
- the invention further provides an apparatus for plasma treating a gas permeable material, the apparatus including:
- the randomised microdischarges provide a generally uniform plasma treatment of the gas permeable material.
- the voltage applying means preferably applies the voltage to the electrodes at a frequency, that enables the dispersion and/or removal, in the moving gas, of plasma by-products, which cause localisation of the plasma microdischarges.
- Any frequency may be employed, but the frequency may be in the range 1-20 kHz, and is preferably in the range 1-5 kHz.
- the electrodes are spaced advantageously to permit the relative movement therebetween of a material and to minimise the power required to generate the plasma.
- the electrode spacing is in the range 2 to 10 mm, most preferably about 4 mm.
- the spaced electrodes are preferably shaped to permit the movement of the gas through the gas permeable material in a direction transverse to the direction of passage of the material between the spaced electrodes.
- a first of the spaced electrodes may be gas permeable, preferably a mesh.
- Neighbouring discrete electrode segments are preferably spaced apart about 0.5 to 2 mm.
- the means enabling the passage of the gas permeable material may include a rotatable drum, a curved surface of the drum comprising the first electrode, the second electrode comprising the discrete electrode segments being concentrically arranged about the drum whereby the gas permeable material rides on the first electrode between the first and second electrodes.
- the apparatus of the invention in either aspect, is especially suitable for the treatment of fibrous materials and textiles, for example wool, particularly wool sliver.
- an electrode for enabling plasma generation including:
- the uniform contact between the liquid medium and the dielectric sheath ensures that the current is distributed evenly across the surface of the dielectric sheath. This facilitates randomized electrical breakdown of the gas between the electrodes, and in consequence a more uniform plasma. It also avoids undesirable concentration of the electric field at sharp points within the electrode structure that increase the probability of dielectric breakdown. This is especially important when thin dielectric media are used, which is preferred in order to maximise the efficiency of coupling of electrical energy to the plasma.
- the liquid conductor also helps to uniformly distribute heat in the electrodes and so minimise thermal stresses.
- the liquid conductor may be transparent and so allow observation and/or optical measurement of the plasma that would not be possible with conventional electrodes.
- the liquid medium preferably has a controllably variable electrical conductivity depending on the composition.
- the electrodes of the second aspect of the invention may take any shape, they are preferably elongate and may be cylindrical.
- FIG. 1 is a cross-sectional schematic view of a plasma treatment apparatus in accordance with a preferred embodiment of the present invention, especially suitable for treating wool sliver;
- FIG. 3 is a diagrammatic perspective view of the apparatus of FIG. 1 without the second electrode;
- FIG. 4 is a fragmentary perspective view and partial cross-section of the second electrode
- FIG. 5 is a perspective view of an alternative arrangement of the second electrode.
- FIG. 6 is a cross-sectional view of a plasma treatment apparatus in accordance with an alternative embodiment of the invention.
- the plasma treatment apparatus 30 includes a hollow rotatable drum 40 having a first electrode, in the form of a mesh electrode 60 , formed on the curved outer surface of the drum 40 .
- the apparatus 30 further includes a second electrode, formed as a plurality of rod electrodes 70 , spaced radially outwardly from the mesh electrode 60 .
- the mesh electrode 60 comprises a coarse mesh 62 supporting an overlying layer of fine mesh 64 .
- the fine mesh 64 prevents localisation of plasma microdischarges by providing a large array of potential plasma forming locations, in contrast to the course mesh 62 where the reduced number of potential plasma forming locations would ordinarily lead to localisation of the plasma microdischarges.
- the drum 40 has a tubular core 44 and a wedge-shaped baffle 42 extending from the core to the outer perimeter of the drum 40 .
- the core 44 extends through the drum 40 and has apertures 46 to permit the flow of a gas from the hollow of the drum 40 to internally of the core 44 .
- the core 44 is attached by a conduit 48 to a suction means 50 , in the form of an industrial blower.
- a motor 52 drives wheel 54 , which wheel 54 driveably engages the drum 40 to enable rotational movement of the drum 40 relative to the rod electrodes 70 .
- suitable plasma treatment of a material depends on the residence time of the material within the plasma, suitable plasma treatments using apparatus 30 have been provided where the rod electrodes 70 cover 0.8 to 1 m of the surface of the drum 40 and the drum 40 is rotated at a rate which moves the wool sliver 56 through the apparatus 30 at a rate approximating 20 m/min.
- the suction means 50 draws a gas, preferably air at ambient atmospheric pressure, between the rod electrodes 70 , through the space between the rod electrodes 70 and mesh electrode 60 , and through mesh electrode 60 into the hollow of the drum 40 and then into the tubular core 44 via the apertures 46 .
- gases such as noble gases, may otherwise be used.
- the gas pressure is preferably ambient atmospheric pressure, gas pressures above and below ambient atmospheric pressure may be used. The particular details of airflow between the rod electrode 70 and mesh electrode 60 will be discussed in greater detail at a later point.
- the air flowing into the hollow of the drum 40 acts to retain the wool 56 in contact with the mesh electrode 60 .
- the wool 60 or other similarly gas permeable material, is retained on the mesh electrode 60 without bunching or folding of the wool 56 during its travel relative to the rod electrodes 70 .
- Removal of the wool 56 from contact with the mesh electrode 60 is facilitated by the baffle 42 because air does not move through the segment of the mesh electrode 60 adjacent to the baffle 42 . Absence of air moving through the mesh electrode 60 in that segment releases the wool 56 from contact with the mesh electrode 60 .
- Satisfactory plasma treatment of material has been achieved by applying an alternating voltage of 10 kV to 20 kV between the mesh electrode 60 and rod electrodes 70 , at any frequency but preferably in the range of 1 to 5 kHz. While the mesh electrode 60 is grounded, the alternating voltage is applied by a power source 85 to the rod electrodes 70 via cables 82 from a suitable busbar.
- the airflow A, B and C is transverse to the direction of movement of the wool 56 as indicated by arrow M.
- the gas moves through the space between the mesh electrode 60 and rod electrodes 70 , and through the wool 56 into the hollow of the drum 40 .
- Air flowing through the material during passage through the regions without plasma acts to disperse or remove plasma products such as ions and undesirable chemicals which remain stationary relative to the material, thereby preventing the onset of travelling burning instabilities.
- the gas flow may be through the space between the mesh electrode 60 and rod electrodes 70 , and through the wool 56 in a direction parallel or anti-parallel with the direction of movement of the wool indicated by arrow M.
- the rod electrodes 70 are spaced by a distance S such that the inwardly flowing gas A is, as indicated by arrows B, caused to turbulently flow over the plasma generating surfaces of the rod electrodes 70 that are adjacent and opposed to the mesh electrode 60 . If the distance S is too great, the inwardly flowing air A flows more slowly and more directly from between adjacently spaced rod electrodes 70 through the mesh electrode 60 with lower air-flow over the surface of the rod electrode 70 . However, if the distance S is too small, the burden placed on the suction means 50 increases and a more powerful suction means 50 is required to achieve an airflow rate which removes remaining ions and randomizes the plasma microdischarges. The applicant has found that a rod electrodes 70 spacing S of 0.5 to 2 mm ensures acceptable and achievable turbulent airflow and airflow rates across the surface of the rod electrodes 70 adjacent the mesh electrode 60 .
- the rod electrodes 70 are optimally spaced from the mesh electrode 60 to enable the travel of the wool 56 therebetween whilst also minimising the power required to generate a plasma microdischarge over that distance.
- the rod electrodes 70 are spaced from the mesh electrode 60 by about 4 mm. However, this distance will vary depending on the gas permeable material placed within the apparatus and may range between 1 and 10 mm.
- the air moving through the space between the mesh electrode 60 and rod electrodes 70 disperses and/or removes ions remaining from a previous plasma generation cycle such that subsequent plasma microdischarges are generated at random locations between the rod electrodes 70 and mesh electrode 60 rather than repeatedly generating at the location of the remaining ions.
- dispersion and/or removal of the ions remaining stationary relative to the electrodes enables randomisation of the plasma microdischarges to provide a generally randomised plasma for treating the wool 56 .
- the high airflow through the wool 56 enables dispersion and/or removal of ions and other plasma products trapped in the wool 56 and thereby avoids burning of the wool 56 due to small intense hot plasmas localised relative to the wool 56 .
- the avoidance of burning instabilities allows greater power density to be used and so provides greater treatment level or allows greater speed to be used for a given treatment length and/or delivery speed.
- the air speed between rod electrodes 70 is ideally greater than 1.8 m/s.
- the minimum air speed depends on the interaction of a variety of parameters, including the power, voltage and frequency, and the material being processed.
- each rod electrode 70 comprises a conductive core 72 , preferably formed of a metallic conductor such as copper.
- a dielectric sheath in this instance formed as a glass tube 76 closed at one end, surrounds the core 72 .
- a conductive medium 74 separates the core 72 from the glass tube 76 .
- the material filling the space between the conductor and the glass may be electrically conducting or nonconducting but is preferably conducting to minimise the thickness of the dielectric barrier and to maximise the uniformity of the electrode.
- the conductive liquid medium 74 in this case water, takes on the shape of the interior surface of the glass tube 76 , thus forming a uniform and intimate contact across the entire interior surface of the glass tube.
- the uniformity of the contact ensures a more even distribution of current, and therefore electrical charge, over the glass tube. Such uniform current distribution thereby facilitates randomization of plasma microdischarges, thus providing a more even plasma treatment of a material.
- the intimate contact between the liquid 74 and the dielectric 77 also maximises the smoothness of the contact between the conductor and the dielectric, reducing localised concentrations of the electric field that could result in electrical breakdown of the dielectric material.
- the liquid conductor also more uniformly dissipates heat, reducing thermally generated stresses in the glass or ceramic electrodes.
- An air space may be provided in a suitable position, not shown, to accommodate expansion and contraction of the liquid with changes in temperature.
- the use of liquid conductors also facilitates the use of dielectric covered electrodes of more complex shapes than otherwise possible.
- Dielectric materials may be shaped by any means into complex configurations, for instance a coiled glass tube, then filled easily with liquid conductors.
- the liquid conductor may be transparent and so allow observation and/or optical measurement of the plasma that would not be possible with conventional electrodes.
- the liquid medium preferably has a controllably variable electrical conductivity depending on the composition.
- the inclusion of selected additives in the liquid controls the electrical conductivity.
- Controlled conductivity may be used to prevent momentary localisation of the electrical energy density over the electrode area on time scales that can generate damaging instabilities.
- the conductive medium 74 is retained inside the tube 76 by a bung (not shown), through which bung protrudes an exposed end of the core 72 .
- the end of the core 72 is connected to an electrical power source by wire 82 for providing the alternating voltage to the rod electrodes 70 .
- the rod electrodes 70 are interleaved such that when the alternating voltage is applied, adjacent rod electrodes 70 have opposite polarity but an electrical potential of the same magnitude. Accordingly the sliver 56 is moved along adjacent to the spaced rod electrodes 70 . In this manner, the plasma microdischarges are generated between adjacent rod electrodes 70 rather than between the rod electrode 70 and mesh electrode 60 .
- the alternating voltage can be halved in contrast to the arrangement in FIG. 4 , ie +/ ⁇ 10 kV, such that the same 20 kV potential difference between adjacent rod electrodes 70 is still generated.
- the electrical excitation to generate the plasma can be applied by grounding either electrode 60 or 70 while applying the full time varying voltage to the other electrode 70 or 60 , respectively.
- the voltage may be applied at any combination of frequencies and voltages to both electrodes simultaneously such that there is a time varying potential difference between them adequate to generate the required plasma.
- One safety feature which may be used on the apparatus 30 is a pair of windows located adjacent of the baffle and through which the wool 56 enters and exits from the space between the rod electrodes 70 and mesh electrode 60 .
- the windows are dimensioned to permit the travel of wool 56 therethrough, however, the size and shape of the windows are selected to prevent a user inserting their hand or fingers into the space between the rod electrodes and mesh electrode, thereby preventing electrocution of the user.
- the apparatus may further include the safety feature of a lockable gate opposite the segment of the drum 40 which is adjacent the baffle 42 .
- the gate preferably includes a logic switch that enables operation of the apparatus only when the gate is locked, thus preventing access to the drum 40 by a user when the apparatus 30 is operating.
- the baffle 40 assists to release the wool 56 from the mesh electrode 60
- a portion of the wool 56 remains attached and proceeds to re-enter the space for plasma treatment between the rod electrode 70 and mesh electrode 60 .
- the stuck portion of wool 56 is overlapped with a freshly introduced portion of wool 56 .
- Their combined thickness may exceed the spacing between the rod electrode 70 and mesh electrode 60 and result in damage or breakage of the rod electrodes 70 .
- an optical sensor is provided opposite the baffle such that when a stuck portion of wool 56 is sensed, the apparatus 30 is shut down.
- the sensor is programmed to trigger shut down of the apparatus only when optical interference of the sensor exceeds 0.25 seconds.
- FIG. 6 shows an alternative apparatus 100 for plasma treating wool slivers 56 .
- the apparatus 100 carries the wool sliver 56 on an endless belt of mesh 104 which forms an electrode.
- the mesh may be of an electrically insulating material and covers a structure that forms the second electrode.
- rod electrodes 102 Spaced above the mesh belt 104 are rod electrodes 102 formed in the same manner as the rod electrodes 70 of the previously described embodiment. The spacing between electrodes 102 and mesh 104 and between adjacent electrodes 102 is set to have the same effect on the airflow as described in the earlier embodiment.
- the structure supporting the mesh may also be shaped such that it directs the air-flow preferentially around the dielectric covered rod-electrodes, for instance by being arranged in a pattern similar to the rod-electrode pattern but with spaces arranged directly below the dielectric covered rod-electrodes.
- a suction means 106 causes air to flow in the direction of the arrows marked F such that the airflow is through the sliver 56 and is transverse to the direction of travel of the sliver 56 . In this manner, active species created by the plasma generated between the electrodes 102 and mesh 104 is drawn through the sliver 56 , thereby treating the sliver 56 .
- the interleaved electrode 70 assembly concept of FIG. 5 may equally be applied to the apparatus 100 such that plasma is generated between adjacent electrodes 102 .
- the plasma products are drawn through the sliver 56 , which travels adjacently to the electrodes 102 , by the transverse air flow F by the suction means 106 .
- This arrangement produces a treatment gradient in the sliver 56 , i.e. the top fibres of the sliver 56 have greater surface treatment than fibres located deeper within the sliver.
- the sliver may be inverted and passed through the apparatus a second time, or using a second apparatus 106 after inverting the sliver.
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Abstract
Description
- This invention relates to a method and apparatus for the plasma treatment of gas permeable materials, for instance, fibrous materials. The invention is particularly useful when applied to wool.
- Plasma treatment of materials is widely used to alter the surface characteristics of the material. The treatment is generally useful where it is uniformly distributed over the surface of the material. When applied to wool fibres, plasma treatments are used to oxidize a lipid layer on the surface of the fibres. Oxidation of the lipid layer makes the wool fibres more receptive to subsequent surface treatments, for instance anti-shrink and pilling-prevention treatments.
- Removal of the lipid layer also increases friction between the fibres. This benefits yam production processes as less twisting is required to form the yam. The lower twisting level enables the yarn to be produced at a greater rate, enabling downstream processes to be run faster and thereby increasing output. Additionally, yams having a lower twist exhibit a softer feel relative to higher twist yams and may be used advantageously to produce commercially desirable softer garments in contrast to garments made from high twist yam.
- Plasma treatment of wool and other fibrous materials should provide an even surface treatment to ensure that the material is receptive to downstream processing in a production line. If the surface of the material is not treated evenly, the downstream processes will not have their designed effect and an inferior product will result.
- Another aspect of plasma treatment is that wool and other fibrous materials are susceptible to being locally burnt during the plasma treatment. Again, in a production line, this is highly undesirable where a continuous supply of material is required. Hence, an optimum plasma treatment should minimise the incidence of localised burning of the material being treated.
- Some of the present techniques for the generation of plasma for treating materials involves the adjustment of the applied voltage and its frequency in order to obtain a stable uniform plasma. Such plasma is usually generated with gas pressures above or below atmospheric pressure. More recently, advances in plasma treatments at atmospheric pressure have involved the use of expensive noble gases to stabilise the plasma in a uniform glow suitable for surface treating materials. The cost of plasma treatments above or below atmospheric pressure or involving noble gases makes them less economically viable. Accordingly, interest has been focussed on plasma treatments in air and at atmospheric pressure.
- Roth et al, in U.S. Pat. No. 5,403,453, teaches that a uniform glow discharge plasma is created at one atmosphere where ions, produced by the electrical breakdown of helium and/or air, are trapped between the electrodes. Roth indicates that the ion trapping increases the lifetime of the ions in the plasma and thereby results in a lower electrical breakdown threshold and a uniform glow discharge. A similar theory is posited in U.S. Pat. No. 6,299,948 to Gherardi et al assigned to L'Air Liquide. According to Roth et al., such trapping is enabled by applying an electrical field alternating at radio frequencies between spaced electrodes. Roth et al. propose a relationship between electrode spacing, electrode voltage and applied frequency that results in ion trapping.
- International patent publication WO 02/094455 discloses a plasma treatment at atmospheric pressure in which a spatially homogenous distribution of microdischarges is achieved over an elongated discharge electrode, by introducing a gas stream at an inclination to the longitudinal axis of symmetry. The relatively complex structure involves multiple channels from a gas distribution chamber.
- U.S. Pat. 5,895,558 describes a plasma treatment station for polymer strip at about atmospheric pressure, but preferably slightly superatmospheric pressure, in which gas is blown from an array of holes in one of a pair of closed-spaced planar electrodes. Turbulent high flow gas delivery is employed to delay and disrupt the formation of a filamentary discharge.
- It is an object of the invention to provide an improved plasma treatment technique for use with gas permeable materials.
- The inventors have recognised that the poor uniformity of normal atmospheric plasma is due to ions, remaining from a previous cycle of plasma generation, causing electrical breakdown to be concentrated through those ions, ie at the same points. A normal dielectric barrier discharge plasma consists of multiple micro-discharges each of a few nanoseconds duration. The plasma is driven by an alternating high voltage applied between the electrodes. Each half-cycle of alternating voltage plasma is generated through a burst of microdischarges. The ions from each microdischarge do not normally disperse easily and, having lower electrical resistance compared to the surrounding gas, cause the microdischarges to occur repeatedly at the same locations. This provides very poor uniformity of treatment and fails to use all of the available gas for generation of useful chemical species by the plasma.
- Further, the localisation of microdischarges increases the probability of generation of a high temperature instability within the plasma that burns the material to be treated. This seems to occur due to the local release by the plasma of particular chemicals from the material surface, possibly where a high concentration of contaminant occurs. The generation of these chemicals changes the nature of the plasma and causes localised excessive absorption of plasma energy and a rapid rise in temperature. Localisation of the microdischarges is believed to result in two effects. Firstly, ions remaining stationary relative to the electrodes cause localisation of the plasma microdischarges between the electrodes and result in uneven and less effective surface treatment. Secondly, trapping of ions and plasma-material by-products in a gas permeable material moving relative to the electrodes causes localisation of the plasma relative to the material and can result in burning of the material.
- It has further been recognised that the localisation of the plasma microdischarges prevents use of the whole gas volume available in generating the plasma and thus limits the concentration of the active species that beneficially modify the surface chemistry of the material.
- The invention, therefore, uses a strong gas flow through the gas permeable material to prevent the formation of localised plasma microdischarges by dispersing and/or removing ions and undesirable chemicals during and between alternating voltage cycles from between the electrodes or from within the gas permeable material. Thus, the invention provides uniform and effective plasma treatment at voltages, frequencies and electrode separations outside the parameters dictated by Roth's theory. Rather than generating a uniform glow discharge as claimed by Roth and others the present invention provides an effective uniform plasma surface treatment using a filamentary but randomised dielectric barrier discharge plasma and without burning the material to be treated.
- The invention provides, in a first aspect, a method of producing a plasma treated gas permeable material, including the steps of:
- (a) applying an alternating voltage between spaced electrodes, at least one of which is covered with a dielectric barrier and at least one of which comprises a plurality of discrete electrode segments, to generate plasma microdischarges between the spaced electrodes;
- (b) passing a gas permeable material between or adjacent to said spaced electrodes; and
- (c ) moving a gas between said electrode segments into and through the space between the electrodes and through the gas permeable material, the gas flowing over plasma generation surfaces of the respective electrode segments and being moved at a rate whereby the gas flow between the spaced electrodes is turbulent and so randomises the plasma microdischarges and disperses plasma product that would otherwise give rise to burning instabilities in the gas permeable material;
- whereby the randomized plasma microdischarges provide a generally uniform plasma treatment of the gas permeable material.
- It will be appreciated that moving the gas through the space between the electrodes disperses and/or removes ions remaining stationary relative to the electrodes. Furthermore, ions caught in the gas permeable material are dispersed and/or removed by the gas moving through the material. Thus the next plasma microdischarge does not repeat at the same point as the previous plasma-microdischarge. The randomised plasma microdischarges therefore provide a time averaged uniform plasma suitable for uniformly treating the surface of gas permeable materials. Accordingly, a gas permeable material treated by this method has better uniformity of surface characteristics and is less likely to be burned by localized plasma microdischarges.
- In the preferred embodiment, the gas moves in a direction transverse to the direction of passage of the gas permeable material between the spaced electrodes.
- In a particularly preferred embodiment the method is facilitated by the step of applying, between the electrodes, a voltage that alternates at a frequency to enable the dispersion and/or removal, in the moving gas, of plasma by-products which cause localisation of the plasma microdischarges. Any frequency may be employed, but the frequency may typically be in the range of 1-20 kHz, and is preferably in the range of 1-5 kHz.
- As an additional benefit, the moving gas not only removes ions, but also noxious plasma by-products, such as O3 and NO2.
- The gas used in the method may be any gas suitable for electrical breakdown to generate a plasma, such as noble gas or a gas inert to the material, but is preferably air. Moreover, the gas used in the method may have a gas pressure above or below atmospheric pressure. Advantageously, the gas pressure is atmospheric pressure.
- The voltage applied to the spaced electrodes is typically in the range 10-25 kV.
- According to its first aspect, the invention further provides an apparatus for plasma treating a gas permeable material, the apparatus including:
- (a) spaced electrode at least one of which is covered with a dielectric barrier and at least one of which comprises a plurality of discrete electrode segments;
- (b) means for applying an alternating voltage between said spaced electrodes to generate plasma microdischarges between said spaced electrodes;
- (c) means enabling the passage of the gas permeable material between or adjacent to said spaced electrodes; and
- (d) means for moving a gas between said electrode segments into and through the space between said electrodes and through the gas permeable material, the gas flowing over plasma generation surfaces of the respective electrode segments and being moved at a rate whereby the gas flow between the spaced electrodes is turbulent and so randomises the plasma microdischarges and disperses plasma product that would otherwise give rise to burning instabilities in the gas permeable material;
- whereby the randomised microdischarges provide a generally uniform plasma treatment of the gas permeable material.
- The voltage applying means preferably applies the voltage to the electrodes at a frequency, that enables the dispersion and/or removal, in the moving gas, of plasma by-products, which cause localisation of the plasma microdischarges. Any frequency may be employed, but the frequency may be in the range 1-20 kHz, and is preferably in the range 1-5 kHz.
- The electrodes are spaced advantageously to permit the relative movement therebetween of a material and to minimise the power required to generate the plasma. Preferably, the electrode spacing is in the range 2 to 10 mm, most preferably about 4 mm.
- In a preferred embodiment, the spaced electrodes are preferably shaped to permit the movement of the gas through the gas permeable material in a direction transverse to the direction of passage of the material between the spaced electrodes.
- In particular, a first of the spaced electrodes may be gas permeable, preferably a mesh.
- Neighbouring discrete electrode segments are preferably spaced apart about 0.5 to 2 mm.
- The means enabling the passage of the gas permeable material may include a rotatable drum, a curved surface of the drum comprising the first electrode, the second electrode comprising the discrete electrode segments being concentrically arranged about the drum whereby the gas permeable material rides on the first electrode between the first and second electrodes.
- The apparatus of the invention, in either aspect, is especially suitable for the treatment of fibrous materials and textiles, for example wool, particularly wool sliver.
- In a second aspect of the invention, there is provided an electrode for enabling plasma generation, the electrode including:
- (a) an electrically conductive element;
- (b) a dielectric sheath about the electrically conductive element; and
- (c) an electrically conductive liquid medium contacting both the electrically conductive element and the dielectric sheath, whereby the liquid medium forms a uniform contact with the dielectric sheath.
- The liquid medium is preferably between the electricity conductive element and the dielectric sheath. The dielectric sheath preferably substantially surrounds or encloses the electrically conductive elements, e.g. so that the latter forms a core of the electrode.
- The uniform contact between the liquid medium and the dielectric sheath ensures that the current is distributed evenly across the surface of the dielectric sheath. This facilitates randomized electrical breakdown of the gas between the electrodes, and in consequence a more uniform plasma. It also avoids undesirable concentration of the electric field at sharp points within the electrode structure that increase the probability of dielectric breakdown. This is especially important when thin dielectric media are used, which is preferred in order to maximise the efficiency of coupling of electrical energy to the plasma. The liquid conductor also helps to uniformly distribute heat in the electrodes and so minimise thermal stresses.
- The liquid conductor may be transparent and so allow observation and/or optical measurement of the plasma that would not be possible with conventional electrodes.
- The liquid medium preferably has a controllably variable electrical conductivity depending on the composition.
- While the electrodes of the second aspect of the invention may take any shape, they are preferably elongate and may be cylindrical.
- Preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings.
-
FIG. 1 is a cross-sectional schematic view of a plasma treatment apparatus in accordance with a preferred embodiment of the present invention, especially suitable for treating wool sliver; -
FIG. 2 is an enlarged cross-sectional view of a portion of the apparatus ofFIG. 1 ; -
FIG. 3 is a diagrammatic perspective view of the apparatus ofFIG. 1 without the second electrode; -
FIG. 4 is a fragmentary perspective view and partial cross-section of the second electrode; -
FIG. 5 is a perspective view of an alternative arrangement of the second electrode; and -
FIG. 6 is a cross-sectional view of a plasma treatment apparatus in accordance with an alternative embodiment of the invention. - Referring firstly to
FIGS. 1 and 2 , it will be seen that theplasma treatment apparatus 30 includes a hollowrotatable drum 40 having a first electrode, in the form of amesh electrode 60, formed on the curved outer surface of thedrum 40. Theapparatus 30 further includes a second electrode, formed as a plurality ofrod electrodes 70, spaced radially outwardly from themesh electrode 60. - The
mesh electrode 60 comprises a coarse mesh 62 supporting an overlying layer of fine mesh 64. The fine mesh 64 prevents localisation of plasma microdischarges by providing a large array of potential plasma forming locations, in contrast to the course mesh 62 where the reduced number of potential plasma forming locations would ordinarily lead to localisation of the plasma microdischarges. - As shown in
FIGS. 1 and 3 , thedrum 40 has atubular core 44 and a wedge-shapedbaffle 42 extending from the core to the outer perimeter of thedrum 40. Thecore 44 extends through thedrum 40 and has apertures 46 to permit the flow of a gas from the hollow of thedrum 40 to internally of thecore 44. Thecore 44 is attached by aconduit 48 to a suction means 50, in the form of an industrial blower. Furthermore, amotor 52 drives wheel 54, which wheel 54 driveably engages thedrum 40 to enable rotational movement of thedrum 40 relative to therod electrodes 70. - A gas permeable material, in this
case wool sliver 56, is fed overroller 58 into theapparatus 30 from a source. Thewool 56 passes into the space between themesh electrode 60 androd electrodes 70 where thewool 56 is subjected to the plasma treatment. The treatedwool 56 eventually exits the space and passes overroller 58′ into downstream processing equipment. - While suitable plasma treatment of a material depends on the residence time of the material within the plasma, suitable plasma
treatments using apparatus 30 have been provided where therod electrodes 70 cover 0.8 to 1 m of the surface of thedrum 40 and thedrum 40 is rotated at a rate which moves thewool sliver 56 through theapparatus 30 at a rate approximating 20 m/min. - In operation, the suction means 50 draws a gas, preferably air at ambient atmospheric pressure, between the
rod electrodes 70, through the space between therod electrodes 70 andmesh electrode 60, and throughmesh electrode 60 into the hollow of thedrum 40 and then into thetubular core 44 via the apertures 46. Alternative gases, such as noble gases, may otherwise be used. While the gas pressure is preferably ambient atmospheric pressure, gas pressures above and below ambient atmospheric pressure may be used. The particular details of airflow between therod electrode 70 andmesh electrode 60 will be discussed in greater detail at a later point. - As the
wool 56 passes into contact with themesh electrode 60, the air flowing into the hollow of thedrum 40 acts to retain thewool 56 in contact with themesh electrode 60. In this manner, thewool 60, or other similarly gas permeable material, is retained on themesh electrode 60 without bunching or folding of thewool 56 during its travel relative to therod electrodes 70. Removal of thewool 56 from contact with themesh electrode 60 is facilitated by thebaffle 42 because air does not move through the segment of themesh electrode 60 adjacent to thebaffle 42. Absence of air moving through themesh electrode 60 in that segment releases thewool 56 from contact with themesh electrode 60. - Satisfactory plasma treatment of material has been achieved by applying an alternating voltage of 10 kV to 20 kV between the
mesh electrode 60 androd electrodes 70, at any frequency but preferably in the range of 1 to 5 kHz. While themesh electrode 60 is grounded, the alternating voltage is applied by apower source 85 to therod electrodes 70 viacables 82 from a suitable busbar. - As seen in
FIG. 2 , the airflow A, B and C is transverse to the direction of movement of thewool 56 as indicated by arrow M. In this manner, the gas moves through the space between themesh electrode 60 androd electrodes 70, and through thewool 56 into the hollow of thedrum 40. Air flowing through the material during passage through the regions without plasma acts to disperse or remove plasma products such as ions and undesirable chemicals which remain stationary relative to the material, thereby preventing the onset of travelling burning instabilities. In an alternative embodiment, the gas flow may be through the space between themesh electrode 60 androd electrodes 70, and through thewool 56 in a direction parallel or anti-parallel with the direction of movement of the wool indicated by arrow M. - The
rod electrodes 70 are spaced by a distance S such that the inwardly flowing gas A is, as indicated by arrows B, caused to turbulently flow over the plasma generating surfaces of therod electrodes 70 that are adjacent and opposed to themesh electrode 60. If the distance S is too great, the inwardly flowing air A flows more slowly and more directly from between adjacently spacedrod electrodes 70 through themesh electrode 60 with lower air-flow over the surface of therod electrode 70. However, if the distance S is too small, the burden placed on the suction means 50 increases and a more powerful suction means 50 is required to achieve an airflow rate which removes remaining ions and randomizes the plasma microdischarges. The applicant has found that arod electrodes 70 spacing S of 0.5 to 2 mm ensures acceptable and achievable turbulent airflow and airflow rates across the surface of therod electrodes 70 adjacent themesh electrode 60. - The
rod electrodes 70 are optimally spaced from themesh electrode 60 to enable the travel of thewool 56 therebetween whilst also minimising the power required to generate a plasma microdischarge over that distance. Whenwool sliver 56 is used in theapparatus 30, therod electrodes 70 are spaced from themesh electrode 60 by about 4 mm. However, this distance will vary depending on the gas permeable material placed within the apparatus and may range between 1 and 10 mm. - The air moving through the space between the
mesh electrode 60 androd electrodes 70 disperses and/or removes ions remaining from a previous plasma generation cycle such that subsequent plasma microdischarges are generated at random locations between therod electrodes 70 andmesh electrode 60 rather than repeatedly generating at the location of the remaining ions. Thus, dispersion and/or removal of the ions remaining stationary relative to the electrodes enables randomisation of the plasma microdischarges to provide a generally randomised plasma for treating thewool 56. Furthermore, the high airflow through thewool 56 enables dispersion and/or removal of ions and other plasma products trapped in thewool 56 and thereby avoids burning of thewool 56 due to small intense hot plasmas localised relative to thewool 56. The avoidance of burning instabilities allows greater power density to be used and so provides greater treatment level or allows greater speed to be used for a given treatment length and/or delivery speed. - Further benefits of the gas movement include (i) turbulent mixing of the gas to make better use of the available gas to generate greater concentrations of the short lived active species that produce the surface treatment of the
wool 56, (ii) the delivery of fresh volumes of air for the generation of active species by the plasma and thus an improved plasma treatment of thewool 56, and (iii) removal of noxious plasma by-products, such as O3, NO2, and other fumes. - By way of example, for a 2
mm electrode spacing 5, the air speed betweenrod electrodes 70 is ideally greater than 1.8 m/s. In general, the minimum air speed depends on the interaction of a variety of parameters, including the power, voltage and frequency, and the material being processed. - As shown in
FIG. 4 , eachrod electrode 70 comprises aconductive core 72, preferably formed of a metallic conductor such as copper. A dielectric sheath, in this instance formed as aglass tube 76 closed at one end, surrounds thecore 72. A conductive medium 74 separates the core 72 from theglass tube 76. The material filling the space between the conductor and the glass may be electrically conducting or nonconducting but is preferably conducting to minimise the thickness of the dielectric barrier and to maximise the uniformity of the electrode. - In an embodiment of the second aspect of the invention, medium 74 is an electrically conductive liquid medium 74. The liquid medium 74 may consist of water or other suitable conductive liquid.
- The conductive liquid medium 74, in this case water, takes on the shape of the interior surface of the
glass tube 76, thus forming a uniform and intimate contact across the entire interior surface of the glass tube. The uniformity of the contact ensures a more even distribution of current, and therefore electrical charge, over the glass tube. Such uniform current distribution thereby facilitates randomization of plasma microdischarges, thus providing a more even plasma treatment of a material. The intimate contact between the liquid 74 and the dielectric 77 also maximises the smoothness of the contact between the conductor and the dielectric, reducing localised concentrations of the electric field that could result in electrical breakdown of the dielectric material. The liquid conductor also more uniformly dissipates heat, reducing thermally generated stresses in the glass or ceramic electrodes. An air space may be provided in a suitable position, not shown, to accommodate expansion and contraction of the liquid with changes in temperature. The use of liquid conductors also facilitates the use of dielectric covered electrodes of more complex shapes than otherwise possible. Dielectric materials may be shaped by any means into complex configurations, for instance a coiled glass tube, then filled easily with liquid conductors. - The liquid conductor may be transparent and so allow observation and/or optical measurement of the plasma that would not be possible with conventional electrodes.
- The liquid medium preferably has a controllably variable electrical conductivity depending on the composition. For example, the inclusion of selected additives in the liquid controls the electrical conductivity. Controlled conductivity may be used to prevent momentary localisation of the electrical energy density over the electrode area on time scales that can generate damaging instabilities.
- The conductive medium 74 is retained inside the
tube 76 by a bung (not shown), through which bung protrudes an exposed end of thecore 72. The end of thecore 72 is connected to an electrical power source bywire 82 for providing the alternating voltage to therod electrodes 70. - One particular arrangement of the
rod electrodes 70 is shown inFIG. 4 . Therod electrodes 70 are seated in apertures inwall 90, which extend radially outwardly from thedrum 40.Seals 80 electrically insulate anexposed end 75 of the core 72, which is connected to a power source bywire 82, from arcing with themesh electrode 60 located on the opposite side of thewall 90. This arrangement is used where the same alternating voltage is applied to therod electrodes 70 whilst keeping themesh electrode 60 grounded such that the plasma microdischarges are generated between therod electrodes 70 andmesh electrode 60. - In the alternative arrangement shown in
FIG. 5 , therod electrodes 70 are interleaved such that when the alternating voltage is applied,adjacent rod electrodes 70 have opposite polarity but an electrical potential of the same magnitude. Accordingly thesliver 56 is moved along adjacent to the spacedrod electrodes 70. In this manner, the plasma microdischarges are generated betweenadjacent rod electrodes 70 rather than between therod electrode 70 andmesh electrode 60. Thus, the alternating voltage can be halved in contrast to the arrangement inFIG. 4 , ie +/−10 kV, such that the same 20 kV potential difference betweenadjacent rod electrodes 70 is still generated. - The electrical excitation to generate the plasma can be applied by grounding either
electrode other electrode - One safety feature which may be used on the
apparatus 30 is a pair of windows located adjacent of the baffle and through which thewool 56 enters and exits from the space between therod electrodes 70 andmesh electrode 60. The windows are dimensioned to permit the travel ofwool 56 therethrough, however, the size and shape of the windows are selected to prevent a user inserting their hand or fingers into the space between the rod electrodes and mesh electrode, thereby preventing electrocution of the user. - The apparatus may further include the safety feature of a lockable gate opposite the segment of the
drum 40 which is adjacent thebaffle 42. The gate preferably includes a logic switch that enables operation of the apparatus only when the gate is locked, thus preventing access to thedrum 40 by a user when theapparatus 30 is operating. - While the
baffle 40 assists to release thewool 56 from themesh electrode 60, occasionally a portion of thewool 56 remains attached and proceeds to re-enter the space for plasma treatment between therod electrode 70 andmesh electrode 60. In this case, the stuck portion ofwool 56 is overlapped with a freshly introduced portion ofwool 56. Their combined thickness may exceed the spacing between therod electrode 70 andmesh electrode 60 and result in damage or breakage of therod electrodes 70. To prevent this overlapping, an optical sensor is provided opposite the baffle such that when a stuck portion ofwool 56 is sensed, theapparatus 30 is shut down. To avoid recurring shut down of the apparatus by stray wool fibres, or other dust particles, the sensor is programmed to trigger shut down of the apparatus only when optical interference of the sensor exceeds 0.25 seconds. -
FIG. 6 shows analternative apparatus 100 for plasma treating wool slivers 56. Instead of a rotating drum, theapparatus 100 carries thewool sliver 56 on an endless belt ofmesh 104 which forms an electrode. Alternatively the mesh may be of an electrically insulating material and covers a structure that forms the second electrode. Spaced above themesh belt 104 arerod electrodes 102 formed in the same manner as therod electrodes 70 of the previously described embodiment. The spacing betweenelectrodes 102 andmesh 104 and betweenadjacent electrodes 102 is set to have the same effect on the airflow as described in the earlier embodiment. The structure supporting the mesh may also be shaped such that it directs the air-flow preferentially around the dielectric covered rod-electrodes, for instance by being arranged in a pattern similar to the rod-electrode pattern but with spaces arranged directly below the dielectric covered rod-electrodes. A suction means 106 causes air to flow in the direction of the arrows marked F such that the airflow is through thesliver 56 and is transverse to the direction of travel of thesliver 56. In this manner, active species created by the plasma generated between theelectrodes 102 andmesh 104 is drawn through thesliver 56, thereby treating thesliver 56. - The interleaved
electrode 70 assembly concept ofFIG. 5 may equally be applied to theapparatus 100 such that plasma is generated betweenadjacent electrodes 102. Again, the plasma products are drawn through thesliver 56, which travels adjacently to theelectrodes 102, by the transverse air flow F by the suction means 106. This arrangement produces a treatment gradient in thesliver 56, i.e. the top fibres of thesliver 56 have greater surface treatment than fibres located deeper within the sliver. If a uniform fibre treatment is desired, the sliver may be inverted and passed through the apparatus a second time, or using asecond apparatus 106 after inverting the sliver.
Claims (52)
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Also Published As
Publication number | Publication date |
---|---|
JP2006525627A (en) | 2006-11-09 |
US20110180387A1 (en) | 2011-07-28 |
WO2004099490A1 (en) | 2004-11-18 |
US8309033B2 (en) | 2012-11-13 |
HK1089799A1 (en) | 2006-12-08 |
EP1623064B1 (en) | 2012-04-11 |
EP1623064A4 (en) | 2008-10-29 |
EP1623064A1 (en) | 2006-02-08 |
ATE553242T1 (en) | 2012-04-15 |
NZ543027A (en) | 2007-06-29 |
JP4914713B2 (en) | 2012-04-11 |
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