Enhancing the Performance of PLA Nonwoven Fabrics Through Plasma Treatments for Superior Active-Molecule Retention

Polylactic acid (PLA) is a promising biobased polymer celebrated for its biocompatibility, biodegradability, and advantageous mechanical properties. However, its inherent hydrophobicity and lack of hydrophilic functional groups restrict its application in advanced uses, such as nonwoven fabrics (NWFs) for masks, diapers, and biomedical products. This study explores the application of cold plasma treatments to modify the surface of PLA-based NWFs using oxygen and oxygen–argon gas mixtures. We varied power levels and exposure times to optimize surface activation. The samples treated with plasma under different conditions were analyzed to understand the impact of these treatments on the surface functionalization, morphology, and thermal properties of PLA_NWF. Additionally, as a proof of concept, the plasma-treated samples were dip-coated in green tea extract, which is rich in (-)-epigallocatechin gallate (EGCG), a natural antioxidant. The findings demonstrate that plasma treatment significantly enhances the adhesion and functionality of the active ingredient, thereby paving the way for innovative sustainable applications of surface-activated PLA-NWFs in the biomedical and cosmetic sectors or food preservation.