With a market demand for low cost, easy to produce, flexible and portable applications in healthcare, energy, biomedical or electronics markets, large research programs are initiated to develop new technologies to provide this demand with new innovative ideas. One of these fast developing technologies is organic printed electronics. As the term printed electronics implies, functional materials are printed via, e.g. inkjet, flexo or gravure printing techniques, on to a substrate material. Applications are, among others, organic light emitting diodes (OLED), sensors and Lab-on-a-chip devices. For all these applications, in some way, the interaction of fluids with the substrate is of great importance. The most used substrate materials for these low-cost devices are (coated) paper or plastic. Plastic substrates have a relatively low surface energy which frequently leads to poor wetting and/or poor adhesion of the fluids on the substrates during printing and/ or post-processing. Plasma technology has had a long history in treating materials in order to improve wetting or promote adhesion. The µPlasma patterning tool described in this thesis combines a digital inkjet printing platform with an atmospheric dielectric barrier discharge plasma tool. Thus enabling selective and local plasma treatment, at atmospheric pressure, of substrates without the use of any masking materials. In this thesis, we show that dependent on the gas composition the substrate surface can either be functionalized, thus increasing its surface energy, or material can be deposited on the surface, lowering its surface energy. Through XPS and ATR-FTIR analysis of the treated (polymer) substrate surfaces, chemical modification of the surface structure was confirmed. The chemical modification and wetting properties of the treated substrates remained present for at least one month after storage. Localized changes in wettability through µPlasma patterning were obtained with a resolution of 300µm. Next to the control of wettability of an ink on a substrate in printed electronics is the interaction of ink droplets with themselves of importance. In printing applications, coalescence of droplets is standard practice as consecutive droplets are printed onto, or close to each other. Understanding the behaviour of these droplets upon coalescence is therefore important, especially when the ink droplets are of different composition and/or volume. For droplets of equal volume, it was found that dye transport across the coalescence bridge could be fully described by diffusion only. This is as expected, as due to the droplet symmetry on either side of the bridge, the convective flows towards the bridge are of equal size but opposite in direction. For droplets of unequal volume, the symmetry across the bridge is no longer present. Experimental analysis of these merging droplets show that in the early stages of coalescence a convective flow from the small to large droplet is present. Also, a smaller convective flow of shorter duration from the large into the small droplet was identified. The origin of this flow might be due to the presence of vortices along the interface of the bridge, due to the strong transverse flow to open the bridge. To conclude, three potential applications were showcased. In the first application we used µPlasma patterning to create hydrophilic patterns on hydrophobic dodecyl-trichlorosilane (DTS) covered glass. Capillaries for a Lab-on-a-chip device were successfully created by placing two µPlasma patterned glass slides on top of each other separated by scotch tape. In the second application we showcased the production of a RFID tag via inkjet printing. Functional RFID-tags on paper were created via inkjet printing of silver nanoparticle ink connected to an integrated circuit. The optimal operating frequency of the produced tags is in the range of 860-865 MHz, making them usable for the European market, although the small working range of 1 m needs further improvement. Lastly, we showed the production of a chemresistor based gas sensor. In house synthesised polyemeraldine salt (PANi) was coated by hand on top of inkjet printed silver electrodes. The sensor proved to be equally sensitive to ethanol and water vapour, reducing its selectivity in detecting changes in gas composition.
Much research effort is invested in developing enzymatic treatments of textiles by focusing on the performance of enzymes at the laboratory scale. Despite all of this work, upgrading these developments from the laboratory scale to an industrial scale has not been very successful.Nowadays,companies are confronted with rapid developments of markets, logistics, and social and environmental responsibilities. Moreover, these organizations have to supply an ever-increasing amount of information to the authorities, shareholders, lobbyists, and pressure groups. Companies have tried to fulfill all of these demands, but this has often led to the loss of focus on new products and process development. However, both theory and practices of breakthrough innovations have shown that those rightfully proud of previous successes are usually not the ones that led the introduction of new technology, as shown and excellently documented by Christensen [1]. The textile industry is no exception to this observation.With the lack of management impetus for new product and process developments, companies began to reduce investments in these activities.However, this results in a reduction of the size of the company or even closure. Besides the hesitation from the top management of textile companies to focus on new developments,middle management level is also reluctant to evaluate and implement developments in new products and processes. One of the reasons for this reluctance is that many processes in the textile industry are notfully explored or known. From this lack of knowledge, it is easy to explain that there is hesitation for change, since not all consequences of a change in processing or production can be predicted. Often new developments cannot be fully tested and evaluated on the laboratory- or pilot-scale level.This is caused by the impossibility of mimicking industrial-scale production in a laboratory.Additionally, pilot-scale equipment is very expensive and for many companies it is not realistic to invest in this type of equipment. Fortunately an increasing number of textile companies have realized that they have to invest in new products and processes for their future survival and prosperity. New developments are decisive for future successes. If such companies decide to invest in new developments, it is clear that with the scarcity of capital for product and process developments, the chance of failure should be minimized. For successful process and product development, it is necessary to organize the development process with external partners because it is clear that it is almost impossible for individual textile companies to control the process from idea generation to academic research, implementation research, and development and industrial testing. These issues are especially characteristic for small- and medium-sized enterprises (SMEs). Herein, the collaboration has been organized on two research levels. The first research level is knowledge and know-how based. The universities and chemical suppliers worked closely together to investigate the new process.The aim was to explore the influence of process conditions and interactions of chemicals in sub-process steps as a result of the treatment.The second level is that of the industrial implementation of the new process. The universities and chemical suppliers worked closely together with different industries to implement the newly developed process. The focus in this part of the research was the interaction between the chemistry of the new process, equipment, and fabrics. A co-operation between the beneficiaries of the new process was established.The selection criterion for the co-peration was “who will earn something with the new process”. To answer this question, the value chain has been drawn as the simplified scheme shown in Fig. 1 [2].
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Synthetic fibers, mainly polyethylene terephthalate (PET), polyamide (PA), polyacrylonitrile (PAN) and polypropylene (PP), are the most widely used polymers in the textile industry. These fibers surpass the production of natural fibers with a market share of 54.4%. The advantages of these fibers are their high modulus and strength, stiffness, stretch or elasticity, wrinkle and abrasion resistances, relatively low cost, convenient processing, tailorable performance and easy recycling. The downside to synthetic fibers use are reduced wearing comfort, build-up of electrostatic charge, the tendency to pill, difficulties in finishing, poor soil release properties and low dyeability. These disadvantages are largely associated with their hydrophobic nature. To render their surfaces hydrophilic, various physical, chemical and bulk modification methods are employed to mimic the advantageous properties of their natural counterparts. This review is focused on the application of recent methods for the modification of synthetic textiles using physical methods (corona discharge, plasma, laser, electron beam and neutron irradiations), chemical methods (ozone-gas treatment, supercritical carbon dioxide technique, vapor deposition, surface grafting, enzymatic modification, sol-gel technique, layer-by-layer deposition of nano-materials, micro-encapsulation method and treatment with different reagents) and bulk modification methods by blending polymers with different compounds in extrusion to absorb different colorants. Nowadays, the bulk and surface functionalization of synthetic fibers for various applications is considered as one of the best methods for modern textile finishing processes (Tomasino, 1992). This last stage of textile processing has employed new routes to demonstrate the great potential of nano-science and technology for this industry (Lewin, 2007). Combination of physical technologies and nano-science enhances the durability of textile materials against washing, ultraviolet radiation, friction, abrasion, tension and fading (Kirk–Othmer, 1998). European methods for application of new functional finishing materials must meet high ethical demands for environmental-friendly processing (Fourne, 1999). For this purpose the process of textile finishing is optimized by different researchers in new findings (Elices & Llorca, 2002). Application of inorganic and organic nano-particles have enhanced synthetic fibers attributes, such as softness, durability, breathability, water repellency, fire retardancy and antimicrobial properties (Franz, 2003; McIntyre, 2005; Xanthos, 2005). This review article gives an application overview of various physical and chemical methods of inorganic and organic structured material as potential modifying agents of textiles with emphasis on dyeability enhancements. The composition of synthetic fibers includes polypropylene (PP), polyethylene terephthalate (PET), polyamides (PA) or polyacrylonitrile (PAN). Synthetic fibers already hold a 54% market share in the fiber market. Of this market share, PET alone accounts for almost 50% of all fiber materials in 2008 (Gubitz & Cavaco-Paulo, 2008). Polypropylene, a major component for the nonwovens market accounts for 10% of the market share of both natural and synthetic fibers worldwide (INDA, 2008 and Aizenshtein, 2008). It is apparent that synthetic polymers have unique properties, such as high uniformity, mechanical strength and resistance to chemicals or abrasion. However, high hydrophobicity, the build-up of static charges, poor breathability, and resistant to finishing are undesirable properties of synthetic materials (Gubitz & Cavaco-Paulo, 2008). Synthetic textile fibers typically undergo a variety of pre-treatments before dyeing and printing is feasible. Compared to their cotton counterparts, fabrics made from synthetic fibers undergo mild scouring before dyeing. Nonetheless, these treatments still create undesirable process conditions wh
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