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Dry, Chemical-Free Surface Treatment for Powder Coated Substrates

Dry, Chemical-Free Surface Treatment for Powder Coated Substrates. June 17-18, 2013 – Columbus, OH. Question:. “Is there a way to improve adhesion of two-component polyurethane adhesives to polyester- and epoxy-based powder–coated surfaces?”.

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Dry, Chemical-Free Surface Treatment for Powder Coated Substrates

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  1. Dry, Chemical-Free Surface Treatment for Powder Coated Substrates June 17-18, 2013 – Columbus, OH

  2. Question: “Is there a way to improve adhesion of two-component polyurethane adhesives to polyester- and epoxy-based powder–coated surfaces?” Source: Products Finishing Magazine, Powder Coating Clinic, April 2013 PC Summit, 2013

  3. Answer: “It is possible to apply an adhesive over a powder. The challenge is to find an adhesive/powder combination that works. You need to select a powder that meets the performance and appearance properties you need, and then work with an adhesive supplier to find the correct adhesive…” Source: Products Finishing Magazine, Powder Coating Clinic, April 2013 PC Summit, 2013

  4. Answer: “…Polyester powder is more likely to provide adhesion than epoxy powder. You can roughen the surface where you need the adhesion, but that may not be feasible. Talk to an adhesive supplier and you should be able to make it work.” Source: Products Finishing Magazine, Powder Coating Clinic, April 2013 PC Summit, 2013

  5. Problem Statement Powder coated materials present downstream bonding issues. Potential Applications • adhesive bonding • label application • decoration (pad printing, silk screening) • foam gaskets PC Summit, 2013

  6. Fundamentals of Paint Adhesion • The molecules in the paint film wet or flow freely over the substrate • Chemical bonds are formed at the interface • The paint film penetrates the roughness on the substrate surface, resulting in mechanical interlocking once the paint dries. Source: www.metalfinishing.com, Fundamentals of Paint Adhesion, Ed Petrie PC Summit, 2013

  7. Surface Wetting PC Summit, 2013

  8. Surface Energy Measurement Low Surface Energy High Surface Energy PC Summit, 2013

  9. PC Summit, 2013

  10. Surface Modification Options PC Summit, 2013

  11. Is There a Perfect Solution? PC Summit, 2013

  12. * ions + + + + free electron e- e- * gas molecule * gas molecule (excited) e- * * * e- + + Plasma: The 4th State of Matter Plasma Solid Liquid Gas Plasma molecule fragment (high- energy) PC Summit, 2013

  13. Flame Treatment • Low ion density • Activation only- little or no cleaning • Thermal distortion • Inconsistent-ambient conditions • Contamination • Liability – open flame • High consumable cost • Metals/mixed materials not possible PC Summit, 2013

  14. Corona Discharge • Better ion density • Activation only- little or no cleaning • Tight application tolerances • Liability - ozone • High voltage at interface • Metals/mixed materials not possible PC Summit, 2013

  15. Vacuum Plasma • High ion density • Cleaning & activation • Complex chemistries possible • Offline process • Not selective PC Summit, 2013

  16. Openair™ Plasma • High ion density • Cleaning & activation • Simple inputs – power/air • In-line process • Selective treatment • Low/no voltage • No ozone • $0.10 to $0.25/hour PC Summit, 2013

  17. Source: Guideline to Bonding Plastics, ANTEC-2013 Michael Oliveira, Henkel PC Summit, 2013

  18. Openair™ Plasma Jet High voltage Current Ionization Gas Inner Electrode Discharge Chamber Ring Electrode (SS casing) Plasma Substrate PC Summit, 2013

  19. * * * * * * * C C C C C C C H H H H H H H H H H H H H H O O O O O O O N N N N N N N N Attack Surface Contamination C PC Summit, 2013

  20. * * * * * * * C C C C C C C H H H H H H H H H H H H H H O O O O O O O N N N N N N N N Remove Surface Contamination C PC Summit, 2013

  21. H C C C C C C C H H H H H H H H H H H Form Functional Sites N * * N O N N * H O O H * O * O N N * N * N C O O PC Summit, 2013

  22. Straight Jet • Focused plasma cleaning & activation • Long term stability • Low consumable parts • Flexible with different nozzles • Speed: up to 70m/min • Gap: 5 to 20 mm • 15 mm max treatment width PC Summit, 2013

  23. Rotational Jet • Wide area plasma cleaning & activation • Long term stability • Low consumable parts • Flexible with different nozzles • Speed: up to 35m/min • Gap: 5 to 20 mm • 50 mm max treatment width PC Summit, 2013

  24. Openair™-Plasma Jet Heads – Rotating Jet PC Summit, 2013

  25. Continuous Monitoring If you can’t see the treatment, how do you know it’s there? Control the Inputs • Voltage • Amperage • Air Flow • Air Pressure • Pulse Frequency • Duty Cycle • Jet Rotation (if required) PC Summit, 2013

  26. Advantages of Openair™ PlasmaCleaning & Activation • Reliable, repeatable, fast • No dilution effect, steady state • No expensive consumables • Surface cleaning of the complete structure of the material • In-line integration = small footprint • Economical and environmentally friendly • No change in bulk properties of substrate PC Summit, 2013

  27. Powder Coating on Plastic! What’s Next? PC Summit, 2013

  28. Q & A/Discussion jeff.leighty@plasmatreat.com 847.783.0622 Ext. 2121 PC Summit, 2013

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