臺灣博碩士論文加值系統

Brass Coating on Fabric by Using Roll-to-Roll High Power Impulse Magnetron Sputtering System for Smart Textiles
Smart textiles have attracted tremendous attention in both academic researches and industrial applications, and thus contributing to an increasing number of products and applications by using various surface alterative accession for creating surface properties. Electrically conductive fabric/yarn are the key components of smart textiles, which could be used in healthcare, medical, sport, and military applications in the near future. Cu65Zn35 brass alloy, inherently antibacterial, highly electrically conductive, corrosion resistant, and low-cost, has been suggested as a potential candidate for smart textile applications. In this study, conductive brass-coated on polypropylene (PP) non-woven fabric and polyethylene terephthalate (PET) yarn have been investigated by using the roll-to-roll high power impulse magnetron sputtering (R2R-HIPIMS) system, which supplies high plasma density for coating with strong adhesion at the low substrate temperature, combined with the specially designed laboratory-scale R2R system for large-scale product evaluation. Hence, the obtained coating is expected to present better than those conventional processes.
Firstly, in the case of PP non-woven fabric, a web speed was optimized. Experimental results show that a uniform brass coating can be deposited with a crystalline face-centered cubic alpha structure. FE-SEM results reveal a uniform brass coating on the PP non-woven fabric. Ultimately, the substrate did not deteriorate under a specific peak power density of 268 W/cm2 (with a peak current of 110 A) at a maximum web speed of 1.5 m/min. The brass coating with an average film thickness of 65 nm over the PP non-woven fabric provides a sheet resistance of 501 Ω/□. It can be lowered even further through repetition of deposition turns, such as from 501 Ω/□ for 1 deposition turn to 88 Ω/□ for 4 deposition turns. It is found that the antibacterial efficiency (tested according to JIS L 1902: 2008) of the coated fabric can be greatly improved the bacteriostatic value S and bactericidal value L (S=5.3, L=3.2), as opposed to the uncoated fabric (S=3.8, L=0.7) against a gram-negative bacterium Escherichia coli (E. coli). After 10 times washing of the brass-coated fabric within 4 repeated deposition turns, it still provides optimal antibacterial efficacy (S=5, L=3.2).
Secondly, in the case of PET yarn, process optimization was studied at a web speed 0.4 and 1 m/min in which a substrate can be deposited safely and stably with a peak target power density of 308-346 W/cm2 without substrate deterioration. Results of the electrical measurement of brass-coated PET yarn show that the electrical resistance of brass-coated PET yarn reduced as the increasing of coating thickness. The film thickness of 105 nm gives a electrical resistance of 428 Ω at a web speed of 1 m/min, and a 215 nm decreases the electrical resistance to 23 Ω at a web speed of 0.4 m/min for testing 2 cm length of yarn.
Finally, based on these features, brass-coated textiles may have great potential for applications in the smart textile industry.

TABLE OF CONTENTS
ACKNOWLEDGMENT i
ABSTRACT iii
TABLE OF CONTENTS v
LIST OF FIGURES vii
LIST OF TABLES x
CHAPTER I. INTRODUCTION 1
1.1. The motivation 1
1.2. The objective of the research 3
1.3. Scope of the thesis 4
CHAPTER II. LITERATURE REVIEW 6
2.1. Smart textiles 6
2.2. Electrically conductive textiles 12
2.3. Application of the electrically conductive textile for smart textile 18
2.4. Sputtering technology for electrically conductive coating 25
2.5. Roll-to-roll manufacturing 32
CHAPTER III. MATERIALS AND METHODS 35
3.1. Target material and substrates 35
3.1.1. Brass target 35
3.1.2. Substrates 36
3.2. Methods 39
3.2.1. The experimental procedure 39
3.2.2. The adjustment of HIPIMS parameters and web speed 40
3.2.3. Microstructural observation and characterization of the brass film 45
3.2.4. Determination of the electrical resistance of the brass-coated 46
3.2.5. Antibacterial activity assessment 49
3.2.6. Durability test by washing 50
CHAPTER IV. RESULTS AND DISCUSSION 53
4.1. Brass-coated PP non-woven fabric 53
4.1.1. Coating process optimization 53
4.1.2. The color of brass-coated PP non-woven fabric 56
4.1.3. Morphology and structure of the brass coating 57
4.1.4. The color fastness of the brass coating for washing 62
4.1.5. Electrical resistance of brass-coated film 63
4.1.6. Antibacterial efficiency of brass-coated PP fabric 65
4.2. Brass-coated PET yarn 68
4.2.1. Coating process optimization 68
4.2.2. Morphology of the brass coating 69
4.2.3. Electrical resistance of the brass-coated PET yarn 70
CHAPTER 5. CONCLUSIONS 72
REFERENCES 76

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