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Increase Bonding Performance with Plasma & Flame Surface Treating
How to Increase Bonding
Performance with In-line Plasma &
Flame Surface Treating
Ryan Schuelke
Enercon Industries
Increase Bonding Performance with Plasma & Flame Surface Treating
Agenda
• Why surface preparation is needed
• Why plasma surface treaters are replacing other preparation techniques
• How plasma systems clean, etch & functionalize surfaces
• How effects of plasma treatment can be measured
• Industry examples from:
– Automotive, Aerospace, Construction, Electrical, Packaging and Assembly
• Application examples include:
– Printing, Bonding, Decorating and Potting
Increase Bonding Performance with Plasma & Flame Surface Treating
Cohesion & Adhesion
When you observe a liquid
beading up on a surface, you
are witnessing
the forces of cohesion
being stronger than the
forces of adhesion.
Interfacial Compatibility of Surface and Coating
Low Free Surface Energy
Increase Bonding Performance with Plasma & Flame Surface Treating
Interfacial Compatibility of
Surface & CoatingTo mechanically or chemically modify a coating or surface to improve adhesion:
• Modified Coating options
– More aggressive
– Solvent-based
• Considerations
– Cost
– Cleanup
– Hazardous
Increase Bonding Performance with Plasma & Flame Surface Treating
Interfacial Compatibility of
Surface & Coating
Mechanical and Chemical Surface Preparation Options
– Primers
Clean-up, consumable, human error
– Chemical Etching
Expensive, but permanent
– Mechanical Preparations
Cost, time, wear parts, clean-up
– Vacuum Plasmas
Capital & consumable cost, time, batch process
–Atmospheric Plasma & Flame
In-line, continuous process, line adaptation
Increase Bonding Performance with Plasma & Flame Surface Treating
Interfacial Compatibility of
Surface & Coating
Selecting a solution:
Permanent surface modification or temporary?
Supplier controlled or your control?
Batch process or in-line?
Pay back goal: initial investment or ongoing operating
costs?
Increase Bonding Performance with Plasma & Flame Surface Treating
What is Atmospheric Plasma?
plasma : n ; “Fourth state of matter”, (Solid, Liquid, Gas, Plasma.)
plasma treatment: Ionized gas that bombards the surface of a substrate & creates a more hydrophilic, micro-etched and functionalized surface.
Blown Ion Plasma Blown Arc Plasma Flame
Increase Bonding Performance with Plasma & Flame Surface Treating
How Plasma Treating Effects Surfaces
Surface Activation is a result of the following processes:
Removal of weak boundary layers – Surface treatment removes surface layers with the lowest molecular weight; at the same time, it oxidizes the uppermost atomic layer of the polymer.
Cross-linking of surface molecules - Oxygen radicals (and UV radiation) help break up bonds and promote the three dimensional cross-bonding of molecules.
Generation of polar groups - Oxidation of the polymer is responsible for the increase in polar groups which is directly related to adhesion properties of the polymer surface.
Increase Bonding Performance with Plasma & Flame Surface Treating
Plasma Treatment Cleans,
Micro-etches & Functionalizes
Clean: Removes organic and inorganic impurities & contaminants
Micro Etch: Increases surface area creating more bonding sites
Functionalize: Increases polar groups to improve adhesion properties.
Increase Bonding Performance with Plasma & Flame Surface Treating
Surface Analysis
Dyne Level
Contact Angle
Peel Strength
Tape Tests
Increase Bonding Performance with Plasma & Flame Surface Treating
Increased Surface Energy Examples
Material Initial Dyne LevelPost Treatment
Dyne Level
Polycarbonate 37 56-72
Polyethylene 32-34 42-60+
Polypropylene 30-34 45-60
Polystyrene 36 52-70
PTFE 30> 35-50
Rigid PVC 33-36 42-60+
TPU 34 40-48
Increase Bonding Performance with Plasma & Flame Surface Treating
Surface Polarity Comparison
Initial Surface Energy
Final Surface Energy Blown Ion
Final Surface Energy Flame
Polar Non Total Polar Non Total Polar Non TotalPP 1.5 28.1 29.7 14.3 35.4 49.6 9.5 35.1 44.6PE 0.3 28.4 28.7 21.4 38.5 59.9 16.9 39.4 56.3PA6 6.9 34.8 41.7 22.1 38.3 60.3 15.8 37.8 53.5PET 0.3 28.4 28.7 27.7 34.6 62.3 5.2 30.7 35.9CF 2.2 35.4 37.6 20.1 37.7 57.2 24.5 36.0 60.5
Increase Bonding Performance with Plasma & Flame Surface Treating
Peel Strength Adhesion Test
0.22
0.02
0.25
0.16
0.27
0.37
0.16
0.2
0.18
0.26
0.45
0.16
0.27
0.21
0.31
0
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
0.5
PP PE PA6 PET CF
Initial Flame Blown Ion
Increase Bonding Performance with Plasma & Flame Surface Treating
Material Type
Surface Treatment is effective on:
Glass, Plastics, Metals & More
Increase Bonding Performance with Plasma & Flame Surface Treating
Who Uses Surface Treating?
Medical
Electronics
Automotive & Aerospace
Wire & Cable
Packaging & Decorating
Folding Cartons
Construction & Assembly
Increase Bonding Performance with Plasma & Flame Surface Treating
Surface Treatment Benefits
& Industries that Use It
Increase Bonding Performance with Plasma & Flame Surface Treating
Folding Carton Applications
Green Bay PackagingApplication: Treat Folding Cartons
Goal: Improve bond strength and enable production speeds
"Previously, folder gluer press speeds were limited by glue application
speed and dwell time; with atmospheric plasma surface treatment,
press speeds can be significantly increased
while maintaining and even
improving quality.”
– Tom Vogel
Plant Engineer- Green Bay Packaging
Increase Bonding Performance with Plasma & Flame Surface Treating
Automotive Applications
Eissmann Automotive GroupApplication: Treat PP substrates prior to gluing
for automotive interiors.
Goal: Increase adhesion and production speeds.
“It took two minutes on average to treat each part
manually, and now it takes about 10 seconds with
the robot. The tolerance with the robot is
0.02mm, which results in incredibly consistent
coverage and far better adhesion.”
– Barrett White
Manufacturing Engineer- Eissmann Automotive
Increase Bonding Performance with Plasma & Flame Surface Treating
Headlamp Applications
Hella Austrailia PtyApplication: Secure a polycarbonate lens
to a PP headlamp assembly with silicone
adhesive.
Goal: Increase bond strength to withstand
high temperatures.
Solution: Plasma Treater integrated with
six-axis robot to follow precise path of
glue track.
Increase Bonding Performance with Plasma & Flame Surface Treating
Assembly Applications
Customer- ConfidentialApplication: Bond liquid potting compound with glass filled polyester
enclosure.
Goal: Ensure bonding compound adhesion to protect internal
components.
Solution: High velocity flame treater with combustion control system
for repeatable treatment.
Not actual product.
Increase Bonding Performance with Plasma & Flame Surface Treating
Assembly Applications
Customer- ConfidentialApplication: Foam filled constructions such as doors and windows.
Goal: Ensure foam bonding.
Solution: High velocity flame treater with combustion control system
for repeatable treatment.
Not actual product.
Increase Bonding Performance with Plasma & Flame Surface Treating
Potting Applications
Customer- ConfidentialApplication: Bond liquid potting compound with glass filled polyester
enclosure.
Goal: Ensure bonding compound adhesion to protect internal
components.
Solution: High Velocity Flame Treater with combustion control system
for repeatable treatment.
Not actual product.
Increase Bonding Performance with Plasma & Flame Surface Treating
Glow Plasma New Technology
• Treats the inside of plastics to improve surface adhesion
• Ionizes gas chemistries at lower power levels than
traditional plasmas
• Treats hard-to-reach places, including:
– Out of line-of-sight
– Recessed cavities
– Complex pathways
Increase Bonding Performance with Plasma & Flame Surface Treating
Review
• Plasma & flame surface treating are used in a wide variety
of industries to improve adhesive bonding.
• Surface treatment cleans, etches & functionalizes surfaces
to improve adhesion.
• Operational benefits may include improved bond strength,
line throughput, reduced waste & improved processes.
• Systems may be integrated with robotic and indexing
systems.
• Free lab testing can help you decide if surface treatment
can help solve your adhesion challenges.
Increase Bonding Performance with Plasma & Flame Surface Treating
Thank you!
www.enerconind.com/treating