Atmospheric-pressure plasma treatment of polyester nonwoven fabrics for electroless plating

Atmospheric-pressure non-thermal plasmas have been increasingly promoted for polymer surface modifications. In this paper, atmospheric-pressure nitrogen plasma was used to render a polyester nonwoven fabric hydrophilic and facilitate absorption of a palladium catalyst in order to provide a catalytic surface for the deposition of electroless nickel. The plasma was produced in a surface barrier discharge generating a thin plasma layer in good contact with the fabric fibers. The optimum quality nickel coating was obtained for a 1 s treatment time. Treatment times in excess of 1 s resulted in a reduction of the nickel plating deposition rate, uniformity and adhesion values. The plasma-induced surface changes were characterized by liquid strike-through time measurements, X-ray photoelectron spectroscopy, and scanning electron microscopy. Because of atmospheric-pressure operation, very short treatment times, and its robustness the method has the potential to be used in line with standard metal plating lines.