Openair-Plasma: Improving the Adhesion of Plastic Surfaces

Atmospheric-pressure plasma technology has already established itself as a game-changer for surface treatment in industrial manufacturing processes, supporting the subsequent processing of plastics. The technology enables the targeted modification of surface properties to prepare them perfectly for the requirements of subsequent processes such as bonding, printing, painting, sealing and coating.

Plasmatreat GmbH, headquartered in Steinhagen, Germany, the world’s leading supplier of equipment and systems in this field, will be demonstrating the benefits of this high-performance and environmentally friendly technology for all types of plastic components live at Fakuma 2024 at Stand 1210 in Hall A1. Together with partners such as Glaub Automation & Engineering GmbH, specialists in automation and industrial software services, and DJM B.V., a provider of customised inkjet solutions, the company will present various systems and applications for plasma technology.

Openair-Plasma expands the range of plastics for material selection

For technical, economic and environmental reasons, a manufacturer’s decision to use a particular type of plastic can have a significant impact on the entire production process – especially with regard to the required adhesion properties, e.g. when applying adhesives or printing. This is where Openair-Plasma technology as a surface pretreatment method plays a decisive role in material selection and substitution. Targeted surface modification of difficult-to-process plastics such as PP and PE significantly increases the adhesion of adhesives and paints in industrial applications. Originally incompatible plastics can often be joined together using plasma. This gives manufacturers the advantage of a wider choice of materials, allowing them to replace expensive engineering plastics with cheaper commodity plastics or recycled materials, for example.

In Friedrichshafen, visitors can see the various applications of plasma technology: the surface activation of plastic components is demonstrated in a PTU1212 (Plasma Treatment Unit). In this application, gentle activation takes place using an Openair-Plasma rotation nozzle. The second nozzle in the PTU is a special PlasmaPlus coating nozzle: by adding a silicon-like precursor to the plasma jet, nano-thin layers can be deposited on plastic surfaces without the use of solvent-based chemicals. Depending on the application, the surface is given different properties, such as an adhesion-promoting property.

Live on stage: Openair-Plasma treatment and subsequent tape application

How plasma treatment works and how the treatment affects plastic surfaces, e.g. when a tape is applied afterwards – all these questions and more will be answered at Plasmatreat in Hall A1 on Stand 1210. First of all, the plasma experts will be demonstrating on the live plasma table how test specimens made of various plastics, such as PP and PE, but also ABS, are activated. At the same time, visitors can have the technology and the effect of plasma surface treatment explained to them. They will then have the opportunity to apply a tape to test specimens on the automated demo system from partner Glaub Automation and prove the effectiveness of the treatment with Openair-Plasma using various tests.

Glaub Automation offers various application heads, with which adhesive tapes (single-sided or double-sided adhesive, with liner or without), pads and foams can be applied fully automatically. Manufacturers appreciate the precision, repeatability and flexibility they get with Glaub Automation systems.

Enhanced adhesion with PlasmaPlus coating on a plastic cup made of recycled material.

Demonstrating injection moulding in a different way: HoliPress 16 manual plastic injection moulding machine
Injection moulding will not be neglected at Plasmatreat this year either: with the manual plastic injection moulding machine HoliPress16 from partner HoliMaker, test specimens made of PP will be activated on one side with Openair-Plasma and then over-moulded with TPU. Visitors will be able to see for themselves the adhesive strength of the TPU on the PP sample. HoliPress enables the production of high-quality, functional prototypes and small series, requiring very small quantities of test material and standardised injection moulds.

Openair-Plasma treatment can be used on both small and large injection moulding machines, automated in the process or even inline in the injection moulding process. In the in-mould plasma process, the plasma nozzle is integrated into the mould. Plasma flows through the channel via an activation channel and integrated exhaust, activating the moulded part.

2 in 1 – Plasma treatment and printing of PP live at Plasmatreat

In cooperation with partner DJM, visitors to the Plasmatreat stand will be able to see how PP luggage tags are treated prior to printing. The entire surface of the plastic tags will be treated with Openair-Plasma and then printed with UV-curing ink. This rotary nozzle can be used to pre-treat small areas of the surface to increase the adhesion of inks, paints or adhesives. The system includes a generator that is compact and easy to use. Interested parties can meet with Plasmatreat’s experts to have their luggage tags printed and see for themselves the effectiveness and functionality of plasma treatment.

New Plasma System for the EPDM Market

Another system on stand 1210 in hall A1 will demonstrate the automated plasma treatment of EPDM door profiles. The system features a compact design. The door profiles are activated with several static nozzles and prepared for the subsequent application of VOC- and solvent-free adhesives and coatings in the form of flock or bonded coatings. Plasma technology also offers significant process advantages for this application. Thanks to the number of nozzles, the profile can be pre-treated selectively or over its entire surface. This plasma system completely replaces conventional pretreatment methods such as mechanical brushing or primer application. This allows manufacturers to increase the level of automation and reproducibility of the pre-treatment process in production while reducing their carbon footprint.

Read more news from Plasmatreat here.

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