Zinc oxide nanoparticles, especially those with a high aspect ratio (i. e., nanorods and nanowires), are of great interest for many applications as they are piezoelectric, photocatalytic and antimicrobial. In the present study, a plasma flight-thru synthesis method was developed that allows controlling the particle size and shape of the zinc oxide nanoparticles. In a direct current thermal plasma reactor operated at atmospheric pressure, zinc powder injected into the plasma jet was molten, vaporized and oxidized, which allowed growing zinc oxide nanoparticles. The particle spectrum ranged from small nanospheres to nanorods, nanowires and multipodic nanoparticles such as tetrapods. The influence of the oxygen rate and the plasma power (correlated to the discharge current) on the particle morphology was studied, and the feasibility of the nanowire-like particles as piezoelectric sensor material was investigated. Piezoelectric test sensors, equipped with the plasma-synthesized zinc oxide nanowires, successfully responded to mechanical stimulation after poling.

Sol–gel coatings have many benefits in industrial applications, thanks to their simple low-temperature preparation processes and easy-to-alter dimensions. However, they often require curing through heating at elevated temperatures or UV radiation, which can increase manufacturing complexity and energy consumption. To overcome this challenge, we propose an alternative method for curing sol–gel coatings quickly and easily using various atmospheric pressure cold or hot plasma technologies, such as plasma jet, diffuse coplanar surface barrier discharge, and gliding arc technology. Our research involves preparing light-transparent sol–gel coatings on stainless-steel substrates via the spin-coating method, using a unique combination of commercially available organic precursors that could be used as water and corrosion-resistant protective paints. We analyse the efficiency of plasma curing by examining the morphological changes, water adhesion, and chemical changes induced by plasma treatment using a scanning electron microscope, contact angle measurement, X-ray photoelectron spectroscopy, nanoindentation, scratch testing, and Fourier transform infrared spectroscopy. According to these measurements, the choice of plasma technology can affect the modification of surface chemistry and water adhesion. The DCSBD plasma changes the surface the most; the layer becomes hydrophilic, not hydrophobic, as with the other curing methods. In addition, post-curing of the layers treated with agliding arc, plasma jet or hotplate can be seen over time. Post-curing is described by the reaction of Si–O–C to Si–O–Si. This reaction path can be easily measured with XPS and FTIR. This post-curing also affects the adhesion of the coating to the substrate. The adhesion improves for all samples, except for the DCSBD-treated sample. However, the coating hardness was increased by the plasma treatment in all samples.

One of the greatest challenges worldwide is containing the spread of problematic microorganisms. A promising approach is the use of antimicrobial coatings (AMCs). The antimicrobial potential of certain metals, including copper and zinc, has already been verified. In this study, polyethylene terephthalate and aluminum (PET-Al) foils were coated with copper, zinc, and a combination of these two metals, known as core–shell particles, respectively. The resistance of the three different types of coatings to mechanical and chemical exposure was evaluated in various ways. Further, the bacteria Staphylococcus aureus and the bacteriophage ϕ6 were used to assess the antimicrobial efficacy of the coatings. The best efficacy was achieved with the pure copper coating, which was not convincing in the abrasion tests. The result was a considerable loss of copper particles on the surfaces and reduced effectiveness against the microorganisms. The core–shell particles demonstrated better adhesion to the surfaces after abrasion tests and against most chemical agents. In addition, the antimicrobial efficiency remained more stable after the washability treatment. Thus, the core–shell particles had several benefits over the pure copper and zinc coatings. In addition, the best core–shell loading for durability and efficacy was determined in this study.

Anti-reflective coatings are crucial in minimizing reflection between different optical media at the interfaces. This study aims to develop an anti-reflective layer for the near-infrared region using a sol-gel coating method combined with a low-temperature plasma-jet-assisted surfactant extraction. For the deposition of the sol-gel layer on glass and polycarbonate substrates, dip-coating and spray-coating techniques were used. Surfactant removal was carried out using a plasma-jet and solvent exchange. Some of the samples were also annealed at 450 °C. The samples were characterized through light transmission measurements, haze percentage determination, 3D laser scanning microscopy, scanning electron microscopy, profilometry, Fourier transform Infrared spectroscopy, ellipsometry and atomic force microscopy. The results showed that the anti-reflective coating layer treated with a plasma-jet and solvent exchange at room temperature demonstrated broadband anti-reflective properties with high transmission in near-infrared regions (up to 7.6% relative improvements in transmission for two sides). Annealing, performed only on the glass substrate, also showed the maximum relative improvement in transmission up to 8% for two sides. Moreover, in the case of polymer-based substrates, a low-temperature process is essential, which is implemented successfully by a plasma-jet method. These findings highlight the effectiveness of the proposed method for fabricating anti-reflective layers on both glass and polycarbonate substrates, offering potential applications in various industries, e.g. where either low-temperature fabrication or cost-cutting, quick and “simple” production methods play a major role for the feasibility of products as in mass markets.

The versatility of sol–gel systems makes them ideal for functional coatings in industry. However, existing coatings are either too thin or take too long to cure. To address these issues, this paper proposes using an atmospheric pressure plasma source to fully cure and functionalize thicker sol–gel coatings in a single step. The study explores coating various substrates with sol–gel layers to make them scratch-resistant, antibacterial, and antiadhesive. Microparticles like copper, zinc, or copper flakes are added to achieve antibacterial effects. The sol–gel system can be sprayed on and quickly functionalized on the substrate. The study focuses on introducing and anchoring particles in the sol–gel layer to achieve an excellent antibacterial effect by changing the penetration depth. Overall, this method offers a more efficient and effective approach to sol–gel coatings for industrial applications. In order to achieve a layer thickness of more than 100 µm, the second part of the study proposes a multilayer system comprising 15 to 30 µm thick monolayers that can be modified by introducing fillers (such as TiO₂) or scratch-resistant chemicals like titanium isopropoxide. This system also allows for individual plasma functionalization of each sol–gel layer. For instance, the top layer can be introduced with antibacterial particles, while another layer can be enhanced with fillers to increase wear resistance. The study reveals the varying antibacterial effects of spherical particles versus flat flakes and the different scratch hardnesses induced by changes in pH, number of layers, and particle introduction.