Large Vacuum Plasma Chamber for Major Automotive Sub-Supplier

pdf downloadA globally recognised automotive sub-supplier supplier reached out to Dyne Technology when facing problems of adhesion to polypropylene interior trim parts for a luxury vehicle. Our customers engineers worked in close partnership with trusted advisors Dyne Technology on the topic of solving adhesion problems to “non-stick” plastics, such as Polypropylene.

Following laboratory testing, the plastic parts were determined to have low surface energy and low polarity, making good adhesion at best difficult but more commonly impossible. After identifying the problem and a solution, The Dyne Technology technical team turned to ensuring that the Plasma Treating solution identified was the best fit for their manufacturing process. With the interior trim requiring surface treatment to increase its surface energy and the manufacturing process requiring the use of a jig system due to a multi-step process, Vacuum Plasma was identified as the best solution to meet our customers’ requirements.

How does the VacuTEC increase adhesion levels?

Vacuum Plasma Chamber Automotive Parts
Inside a Vacuum Plasma chamber treating automotive parts

The ideal solution for the surface activation of the polypropylene interior trim is the highly effective Vacuum Plasma unit – the VacuTEC.

The VacuTEC utilises a vacuum pump to remove most of the air from a large chamber. When the chamber pressure reaches the required level the remaining air in the chamber is super ionised creating what is known as plasma, this occupies the chamber for a pre-determined time and can attach to the material’s surface resulting in the formation of additional polar groups which increases the material’s surface energy. The resulting modified surface has a strong chemical attraction to inks, paint, coatings, adhesives etc. leading to significantly enhanced surface energy and therefore adhesion.

The VacuTEC Vacuum Plasma Unit

Dyne Technology engineers worked closely with our customers engineers throughout the project conducting a large range of process trials and studies before agreeing a detailed specification.

Vacuum Plasma Chamber Automotive Sub-SupplierThe large chamber size is able to surface treat multiple interior trim components at once using a jig system bespoke to the customer. The high intensity Plasma is able to treat a complete jig of components within a 60 second cycle.

The VacuTEC is easily integrated into production facilities, complete with a vacuum pump, the unit requires only a compressed air and mains electricity connection to be operational. This plug and play technology ensures that the unit is easy to use but most importantly, instantly operational.

Equipped with remote access features the VacuTEC allows monitoring of machine performance and allows easy access to the unit if any difficulties arise, minimising downtime and optimising production output.

Giving back control…

Our customer are now in full control of their manufacturing process with the VacuTEC removing the need to outsource surface treatment to external suppliers, this reduces costs and gives control on time scales. Arguably most importantly, the VacuTEC provides an easily repeatable process to ensure consistent levels of surface activation.

If you’d like to find out more about how Plasma can improve adhesion to “non-stick” plastics and examples of our automotive installations, why not give the Dyne Technology engineers a call on +44(0) 1543 411 460.

High Technology Vacuum Plasma Replacement Boosts Performance for Amphenol UK

Dyne Technology, the UK and Ireland’s Number One Plasma Treating equipment supplier, have worked closely with renowned interconnect solutions manufacturer, Amphenol UK to upgrade their Plasma Cleaning process.

Amphenol, based in Kent, offer a full design and manufacturing service for a large range of military and industrial connectors and interconnect solutions, including cable assembly, over-moulding and electronic packaging. The Amphenol team reached out to Dyne Technology when seeking to upgrade their Vacuum Plasma unit which was both activated the polymer surface and cleaning the metal made electrical connectors. This dual surface activation process ensures both the metal is clean and the polymer is “activated”, ensuring good adhesion in one uniform process!

How does Plasma Cleaning work?

Vacuum Plasma chamber
Inside a Vacuum Plasma chamber

Plasma treating is ideal for the high demands of the electrical manufacturing industry. The inherently clean treatment process is free from any electrical potential, making it the perfect surface preparation for components containing electrical circuits. The clean, potential free discharge ensures that circuits are not subjected to electrical discharge during the treating process for both surface activation and surface cleaning.

Plasma Cleaning is excellent at removing organic contaminants from the metals surface as within the Plasma are many excited particles, from electrons to short wave UV light photons. When these species are excited by a high energy discharge, they effectively scrub the surface, thoroughly cleaning it.

Vacuum Plasma is ideal for complex geometry parts and ensuring consistent cleanliness, as the high energy discharge effectively cleans difficult to reach areas of the part being treated.

The VacuLAB Vacuum Plasma Chamber

Laboratory Vacuum Plasma chamberThe VacuLAB was chosen as the ideal replacement for their previous Plasma Treatment system. The VacuLAB offers the same high performance as Dyne Technology’s large VacuTEC Vacuum Plasma chambers, but simply in a smaller benchtop size – ideal for cleaning Amphenol’s small and low volume production electrical connectors. The VacuLAB offers a swift treatment time, increasing Amphenol’s production throughput and the Vacuum Plasma technology ensures that even hard to reach areas are cleaned efficiently, increasing product performance.

Easy to use and set up, the VacuLAB requires 240v, 13A electrical supply and comes with its own vacuum pump, making it operational within minutes. Featuring operator friendly touch screen control, the unit is quick and easy to use, with easily adjustable key parameters (i.e. treatment power, time and vacuum level) allowing operators to have total process control.

Speak to the Experts

Are you interested in finding out more about Vacuum Plasma treatment?

The UK based Dyne Technology Plasma Treatment experts are on hand, just give us a call on +44 (0) 1543 411 460 or complete the form on our contact us page.

Vacuum Plasma Treatment Improves Adhesion for Aston Martin

VacuTEC Aston Martin

The luxury automotive manufacturer who needs little introduction, Aston Martin, has utilised Plasma Treating into their manufacturing process.

Aston Martin has successfully installed the latest in High Technology Vacuum Plasma systems to surface treat the Polypropylene upper body components for their highly anticipated new vehicle release. Installed in their state of the art facilities at Gaydon, the VacuTEC is set to provide a wealth of benefits for Aston Martin’s manufacturing process.

Working with the engineers at Lichfield based Dyne Technology, the team has developed a process to solve the common problem of achieving strong adhesion to low surface energy materials, also known as low or non-polar material’s such as PP,PE,HPDE and many more.

Aston Martin faced the problem of adhesion as high quality hand crafted leather trim was to be bonded to the interior trim mouldings to give the interior of the vehicle the iconic Aston Martin style. The interior trim mouldings require surface treatment prior to adhesion and vacuum plasma presented the ideal solution to modify the surface of the interior trim by increasing its polarity.

“Dyne Technology were the perfect partner for us, they offered excellent local support, adopted a flexible approach to ensure we received the solution that was right for us and were both technically and commercially competitive. An unbeatable combination.” – Carl Daniels, Spokesman for Aston Martin

How does Vacuum Plasma help to solve the problems of adhesion?

Vacuum Plasma unitThe ideal solution for the surface activation of the interior trim moldings is the highly effective Vacuum Plasma unit – the VacuTEC. The VacuTEC is composed of a large vacuum plasma chamber, using a vacuum pump most of the air is removed from this sealed chamber. The chamber pressure will then reach the required level of remaining air (or other gas) and is subjected to a strong electrical field.

This strong electrical field ionises air and other gases, this super ionised air, also known as plasma then occupies the treatment chamber. The resulting modified surface has a strong chemical attraction to inks, paint, coatings, adhesives etc. leading to significantly enhanced surface energy and therefore adhesion.

Vacuum-Plasma-TreatmentThe VacuTEC installed at Aston Martin by Dyne Technology Ltd has a capacity of nearly 1m³ with two internal treatment trays. The VacuTEC is not only easy to use but incredibly effective, the unit can treat a complete car set of upper body environment in one go with a treatment time of just 45 seconds.

Taking back control

The installation of the “VacuTEC” has given Aston Martin the ability to take complete control of the plasma treating process in house. This brings a large number of benefits, discounting the need to use external suppliers to treat parts prior to build, this reduces costs, gives control of time scales, eliminates the risk of damage during process and ensures process consistency.

The VacuTEC is mounted on wheels to allow easy relocation throughout the production facility and comes complete with its own vacuum pump. Dyne Technology engineers worked closely with Aston Martin throughout the project conducting a large range of process trials and studies before agreeing a detailed specification. After delivery, Dyne Technology’s UK based experts installed and commissioned the unit before conducting on-site training for the Aston Martin maintenance and production teams.

Are you having problems with adhesion?

Question ButtonIf you’re experiencing problems with adhesion, you can get in touch with the Dyne Technology team on +44(0) 1543 411 460 or by emailing info@dynetechnology.co.uk.

Corona Treatment of Polypropylene Sheets for ARM Buildings

ARM Buildings Limited, one of the largest suppliers of pig buildings within the UK, have been operating within the industry for thirty-five years. Their long history of product development has undoubtedly helped to cement their outstanding reputation for being a high quality service provider for both the engineering and building industries.

ARM Buildings contacted Dyne Technology when seeking a solution to gaining strong adhesion to the internal polypropylene panel cladding used to build the high quality pig buildings.

With over 40 years industry experience, UK based Dyne Technology were confident that by working closely with the ARM Buildings team, a solution could be found that would both solve the problems of adhesion and optimise their manufacturing process. Working together with the engineers at Lichfield based Dyne Technology, the ARM Buildings team has implemented a solution to improve the adhesion of the low surface energy polypropylene internal cladding.

“Dyne Technology is the perfect partner for us, they offer excellent UK based support, have a very flexible approach and they were both technically and commercially competitive”. – Andrew Brittain, Operations Director – ARM Buildings

Corona Treating PolypropyleneThe most appropriate Surface Treatment Technology was proven to be the Foam and Board Corona Treating unit, used to modify the surface of the polypropylene internal face panel. Corona Treating significantly increases the polypropylene’s polarity, which significantly contributes to the level of adhesion that can be achieved, prior to bonding onto the stud frame and insulation.

Corona Treatment of Polypropylene sheets

The Dyne Technology team worked closely with the engineers at ARM Buildings to ensure the specification of the Corona Treating unit met their exact requirements. Single and dual sided treatment systems are available with a treatment width of up to 3 metres wide and a board thickness of up to 50mm. In this instance only a single side of the polypropylene panel needed to undergo surface activation which brought ARM Buildings considerable cost savings.Foam and Board Corona Treating

The board and foam Corona Treating unit is mounted on wheels to allow easy relocation within the production facility, giving flexibility to ARM Buildings’ manufacturing process. The unit is equipped with an automatic sliding door which enables easy access to the treating area for cleaning or maintenance.

The unit is also equipped with safety switches and interlocks to ensure safe use, while an ozone extraction and filter system is supplied which eliminates ozone generated during the treatment process ensuring safe use. After delivery, Dyne Technology’s UK based experts installed and commissioned the unit before conducting on-site training for the ARM Buildings production teams.

Do you need to speak to an expert?

If you’re facing the problems of adhesion and are seeking an economical, efficient and effective solution, get in touch with us today.

Call us logoAs the UK and Ireland’s Number One supplier of Plasma and Corona Treatment equipment, the Dyne Technology technical experts are best placed to provide trusted advice to help you solve your problems of adhesion. You can contact us on +44(0) 1543 411 460 or email support@dynetechnology.co.uk.

Vacuum Plasma for F1 Giant Red Bull

For more than a decade, Red Bull Racing has forged a unique path in sport’s most technologically advanced and competitively compelling arena – Formula One.

Red Bull reached out to Dyne Technology when seeking new and advanced technology to both super clean metals and activate the surface of non-stick materials such as PEEK and carbon fibre.

Vacuum Plasma TreatmentFollowing in depth discussions with the Dyne Technology Plasma experts, Vacuum Plasma technology was determined to be the best solution for Red Bull due to the flexibility it brings. The large Vacuum Plasma chamber size is compatible with multiple component sizes and multiple parts can undergo treatment at once.

Vacuum Plasma offers a uniform and reproducible process, swift treatment times and ensures optimum adhesion properties for the PEEK, Carbon Fibre and various metal components such as Titanium and Aluminium after undoing Plasma Surface Treatment. Following installation and recognition of all of the benefits Vacuum Plasma added to their R&D and production process, Red Bull purchased a second unit with a considerably bigger chamber size to accommodate  larger components.

How do we Plasma Clean metals?

Our incredible novel technology super cleans the surface of the material undergoing treatment which in turn increases the strength of bond that can be achieved.

Vacuum Plasma WindowPlasma is created when a gas, in this instance and many others, compressed air, is subjected to a high energy discharge: the gas breaks up into electrons, ions, highly reactive free radicals, short wave UV light photons and other excited particles. When these species are excited by a high energy discharge, they effectively scrub the surface to be cleaned and is effective even on difficult to reach areas.

How do we surface activate composites and plastics?

The VacuTEC is composed of a large Vacuum Plasma chamber, using a vacuum pump most of the air is removed from this sealed chamber. The chamber pressure will then reach the required level of remaining air (or other gas) and is subjected to a strong electrical field.

This strong electrical field ionises air and other gases, this super ionised air, also known as plasma then occupies the treatment chamber. The resulting modified surface has a strong chemical attraction to inks, paint, coatings, adhesives etc. leading to significantly enhanced surface energy and therefore adhesion.

As Vacuum Plasma is a cold Plasma, you will not experience and marking or grinning of composites – in fact, you won’t even be able to tell we’ve been there!

Pushing the boundaries of innovation…

The installation of the VacuTEC Vacuum Plasma unit has given Red Bull Racing the ability to take complete control of the Plasma Treatment process in house. This brings a large number of benefits, discounting the need to use external suppliers to treat parts prior to build, this reduces costs, gives control of time scales, eliminates the risk of damage during process and ensures process consistency.

Most importantly, the novel technology ensures innovative R&D on new materials development for Red Bull Racing helping them stay ahead of the curve.

Are you having problems with adhesion?

If you’re experiencing problems with adhesion, you can get in touch with the Dyne Technology team on +44(0) 1543 411 460 or by filling in the form on the Contact Us page.

Plasma Treatment of Polypropylene Medical Implants

Dyne Technology, the UK and Ireland’s Number One Plasma Treatment supplier, has supplied a leading medical device manufacturer with the VacuTEC 2020. Our customer reached out to the Dyne Technology engineers when facing the problems of adhesion to a polypropylene made implanted medical device. The “non-stick” nature of the polypropylene made attempting adhesion impossible and our customer required a repeatable and reliable method of surface activation.

Following in-depth discussions and collaborative testing with Dyne Technology engineers, the state-of-the-art, NEW and high technology VacuTEC 2020 Vacuum Plasma unit was chosen as the surface activation method of choice.

How does it work?

The perfect Plasma Treating technology for you is dependent on several factors including material, application and your production process.

Our customer required the entirety of the medical implant to undergo Plasma Surface Treatment; Vacuum Plasma Treatment of medical implants is excellent as the entirety of the part undergoes treatment  due to the highly active environment within the Plasma chamber. Atmospheric Plasma is better suited for parts undergoing targeted treatment.

Vacuum Plasma Treatment Polypropylene Medical ImplantThe VacuTEC 2020 provides an easily repeatable surface activation which utilises tried and tested Plasma technology to increase the surface energy of the polypropylene medical device. Dyne Technology worked with our customers engineers to determine the important treatment parameters, including time and power output, to ensure optimum performance.

The unit is named because of its chamber size which is 20cm x 20cm, offering the perfect size for our customer; the VacuTEC 2020 was designed to bridge the gap between our standard laboratory Vacuum Plasma unit, the VacuLAB and our custom sized VacuTEC units which can have chambers of up to several cubic metres in size to suit the customers’ needs.

Why Vacuum Plasma?

The VacuTEC2020 utilises the same principles as both our laboratory and full size Vacuum Plasma units.

Question ButtonUsing a vacuum pump, the majority of air is removed from the sealed Plasma chamber, the chamber pressure is then lowered to achieve the required level of gas. The remaining gas (usually air) is then subjected to a strong electrical field which ionises the gas within the chamber, creating Plasma.

Vacuum Plasma Treatment Polypropylene Medical ImplantThe Plasma chamber is a highly active environment where free radicals and other excited particles can attach to the surface of the polypropylene medical device. The formation of these additional polar groups significantly increases the quality of adhesion that can be achieved.

The unit has given our customer control of the Plasma Treating process allowing for their engineers to have control over quality assurance which is of paramount importance.

The bench top unit is also ideal for future research and design, trials and treating small batch quantities of plastics, ceramics, metals and glass.

Vacuum Plasma Treatment Polypropylene Medical ImplantHere’s the clever new addition, the VacuTEC2020 comes with the capability to add different gases; the choice of gas will be dependent upon the functionality you wish to achieve and the material being treated. Complete with two external gas connectors, you can mix the percentage of gases you wish to achieve; that is if you wish to use any “special” gases as in many cases, compressed air is the perfect choice.

Easy to use and set up, the plasma generator requires only a 240v, 13A electrical supply and comes with a vacuum pump that can be sized to suit the customers’ production demands. The whole system can be operational within minutes. Featuring operator friendly touch screen control, the unit is quick and easy to use, with easily adjustable key parameters (i.e. treatment power, time and vacuum level) allowing operators to have total process control.

Speak to the Plasma Treatment experts!

Call us logoIf you’re facing a similar problem to our customer, why not get in touch? With over 40 year’s practical industry experience, the Dyne Technology team are best placed to provide trusted advice and guidance on how to solve the problems of adhesion.

You can get in touch with us by calling +44(0) 1543 411 460 or alternatively email support@dynetechnology.co.uk.

Plasma Cleaning Plastic before Ultrasonic Welding

pdf downloadDyne Technology Ltd, the UK and Ireland’s Number One supplier of Plasma Treatment technology, look at how Plasma improves the surface cleanliness of plastics and how this was beneficial for our customer prior to ultrasonic welding.

A customer approached Dyne Technology when searching for a green and economical method of cleaning a 3D polyolefin component prior to the ultrasonic welding of small plastic brackets. Plasma Cleaning offers a clean, green alternative to nasty environmentally damaging solvent based cleaners which the customer desperately wanted to avoid.

Why Plasma Cleaning?

Plasma Cleaning Plastic and MetalMany are aware that Plasma provides a fast and effective treatment for the removal of organic contaminants from the surface of metal, glass and ceramic components; however, it is not widely known that Plasma is also excellent for removing organic contaminants from the surface of plastics.

How does it work? Plasma is created when a gas (usually compressed air) is subjected to a high-energy discharge: the gas breaks up into electrons, ions, highly reactive free radicals, short wave UV light photons and other excited particles. When these species are excited by a high-energy discharge, they effectively scrub the surface to be cleaned.

The type of Plasma Treatment equipment required is heavily dependent on the component undergoing treatment and your manufacturing process. In this instance, Atmospheric Plasma was the cleaning method of choice, but Vacuum Plasma also provides a uniform and reproducible process for the removal of organic contaminants from the material’s surface.

Atmospheric Plasma Surface Cleaning

Both Vacuum and Atmospheric Plasma can be used for surface cleaning plastics, however which one is right for you is highly dependent on your application.

Plasma Cleaning Plastic and MetalAtmospheric Plasma offers an excellent option for those looking for targeted surface cleaning, perfect for our customer’s application of applying small plastic brackets.

Atmospheric Plasma can easily be integrated with both new and existing production lines; typically, integration with automation offers an excellent solution for targeted treatment areas due to the repeatability and consistency of treatment offered.

The Dyne Technology team has vast experience designing a breadth of robotic Plasma Treatment units, including robotic Atmospheric Plasma cells. When integrating Atmospheric Plasma with automation, the Dyne Technology engineers are always keen to ensure that the unit is both easy to operate and maintain alongside having a compact design and small factory footprint.

Automated Atmospheric PlasmaThe PlasmaTEC-X Atmospheric Plasma system is an economical, environmentally friendly and efficient method of surface activation. Our customer required only a single nozzle, however if the need arises, production can easily be increased as up to eight Plasma nozzles can be operated from a single control box, even if they’re several metres apart.

The unit features a timer mode and boasts simultaneous and independent nozzle operation for true flexibility. Adjustable parameters allow for reliable and consistent surface activation and this is furthered by our “AirSave” feature which continuously monitors compressed air flow to ensure that the unit is consistently running at its optimum performance levels.

Dual Performance Technology

Did you know that following continued treating, Plasma will also “activate” the surface of plastics? Plasma Surface Activation is a highly effective, long lasting method of increasing the surface energy of plastics and rubbers, such as Polypropylene (PP) and Polyethylene (PE).

eco_friendlyThe increased surface energy allows for better wetting of adhesives, coatings and inks alongside contributing to a better chemical affinity between the adhesive and the substrate.

It’s important to note that Plasma Treating doesn’t alter the bulk property of the material, in fact, you won’t even be able to tell we’ve been there.

Let’s Chat!

Call us logoAre you having problems with adhesion? Are you looking to super clean plastics, metals, ceramics or glass? The Dyne Technology technical engineers are only a phone call away.

Give us a call on +44(0) 1543 411 460 to discuss whether Plasma Treatment could have a place within your manufacturing process. We also offer sample treatment from our state-of-the-art laboratory located in Lichfield, the heart of the Midlands to determine whether surface activation is right for you.

Goodbye Flame Treatment, Hello High Performance Plasma

Dyne Technology, the UK and Ireland’s leading Plasma Treatment technology supplier has worked closely with market leading thermoplastic hose and tube manufacturer, Copely Developments, to upgrade their surface activation process.

copely-developmentsProblems of adhesion were not uncommon for Copely Developments when manufacturing their extruded hoses, tubes and profiles for many applications from pneumatics, air brakes, fire detection systems to garden hoses. Surface activation prior to printing is critical as without it, the inkjet print simply rubbed off. Copely Developments Ltd contacted Dyne Technology when seeking to replace their old inefficient flame treatment system.

The engineering team at Copely explored alternatives to Flame Treatment because of the unreliable performance it delivered and the lack of control it allowed over their production process. The lack of consistent results presented huge issues as safety critical markings are printed onto the fire detection tubes which require a strong bond to ensure high print resiliency.

warning-838655_960_720Alongside poor print adhesion the high running cost of Flame Treatment was another important deciding factor for Copely Developments. The Flame Treatment system needed frequent gas bottle replacement. The use of a naked flame in Copely’s thermoplastic extrusion facility presented a significant health and safety concern, this is often reflected in the higher cost of buildings insurance to manufacturers using this process.

Why Plasma Treatment?

The hoses are produced on two separate extrusion lines with speeds ranging from 5 – 30 metres per minute and a flexible and easily repeatable, in-line method of surface activation was essential.

copely-developments-nozzleWorking closely with Copley’s engineers the Dyne Technology technical team conducted initial tests at the Dyne Technology Technical Centre and established that the most appropriate surface treatment method was PlasmaTEC PLX atmospheric Plasma. The next step was to carry out an on-site on-line production trial with the selected PlasmaTEC equipment to satisfy both the Technical and production teams at Copely Developments.

 “The Dyne Technology team provided fantastic customer support in helping us determine the best method of surface activation for our manufacturing process by conducting a “no fuss on site trial” on our production line. We are thrilled with the high performance PlasmaTEC-X as it provides consistent, reliable results and is much cheaper to run than the flame system installed previously. PlasmaTEC-X Plasma Treatment provided us with a repeatable method of surface activation that we can trust to provide consistent results every time. – Steve Walton, Operations Director

The PlasmaTEC-X

nozzle-1The PlasmaTEC PLX Atmospheric Plasma system is an economical, environmentally friendly and efficient method of surface activation. Copely Developments required a multi nozzle Atmospheric Plasma set up, with two Plasma nozzles operating on separate lines. Utilising eight metre nozzle hoses, both Plasma nozzles are operated from a single control box despite being several metres apart.

Up to eight nozzles can be operated from one control panel with the PlasmaTEC-X and an easy to set up timer mode allows for both simultaneous and independent nozzle operation. Adjustable parameters allow for reliable and consistent surface activation and this is furthered by “AirSave” which continuously monitors compressed air flow to ensure that the unit is consistently running at its optimum performance levels.

eco_friendlyThe high running costs experienced with Flame Treatment are now a thing of the past thanks to Atmospheric Plasma Treatment. The PlasmaTEC-X boasts plug and play technology, running off a standard 13 Amp mains electrical supply and factory compressed air, this system offers our lowest cost of ownership Atmospheric Plasma unit yet.

Our intelligent plasma system automatically reports when the plasma tip needs replacement, removing the guess work for consumables replacement, minimising unexpected downtime and reducing the cost of consumables as parts are replaced only when necessary.

Do you want to find out more?

Call us logoDyne Technology is the UK and Ireland’s Number One Plasma Treating technology supplier. If you feel Plasma Treating could have a place in your production and engineering processes, please do not hesitate to get in touch!

Multi Axis DBD Plasma (Corona Treatment) of Bollards

pdf downloadDyne Technology, the UK and Ireland’s Number One supplier of Plasma Treatment equipment has vast experience throughout a multitude of industries.  Surface Treatment often plays an important part in manufacturing a variety of large two and three-dimensional plastic items; Examples of these include 2D flat sheets and 3D components including bollards and signage prior to coating or fixing of label adhesives.

Our customer approached Dyne Technology after having trouble achievin =g good adhesion of the labels due to the “non-stick” nature of the polyethylene (or similar materials) made bollards. It was vital to ensure good adhesion of the safety critical reflective labels and ensure the bond was strong enough to withstand being exposed to the elements.

Plasma Treatment of BollardsFollowing a series of tests undertaken by Dyne Technology engineers, it became clear that the surface needed to be “activated” to achieve the high level of adhesion required. After in-depth discussions with our customer to better understand their manufacturing process and important pre-requisite requirements, the most appropriate solution was determined to be a Multi Axis DBD Plasma (also known as Corona Treatment) unit.

The Solution

SpotTEC Corona TreatmentThe SpotTEC unit is cost effective solution to the problem of improving both the surface energy and wettability of solid materials. A multi axis treatment system, utilising SpotTEC technology, was determined the most appropriate method of implementing surface treatment into the customer’s production unit.

Corona Treatment of BollardsThe system is constructed from extruded aluminium and stainless steel and has a specially designed machine bed to accommodate the product to be processed. The unit is operated via a touch screen Human Machine Interface (HMI) and is easy to operate for control and programming purposes. Through the HMI the operator can view the current machine status, axis positions, total product count, machine status and current cycle stage; The HMI also allows the machines axes to be moved in manual mode and all aspects can be tested prior to operation.

The Surface Treatment Process

DBD Plasma Treatment of BollardsThe bollard is manually positioned on the location bed and the start button is pressed. The unit then automatically moves the SpotTEC Corona Treatment head accurately and repeatedly over the surface to be treated to ensure consistent results.

The machine’s axis and drive units are safely enclosed behind a safety screen with light guard to the access area to allow for quick and safe access to the load/unload area. The simple design of the unit allows the user to set the optimum treatment level for the corona treatment nozzle/s giving the customer true flexibility.

Could Plasma Treating be for you?

Call us logoIf you think Plasma Treating could provide one easy solution for you, please do not hesitate to get in touch with the Dyne Technology team. You can contact our technical experts by calling +44(0) 1543 411 460 or emailing support@dynetechnology.co.uk.

Plasma Treating Changes Functionality of Graphene

pdf downloadHaydale, the well-known UK based company with a mission for enabling technology for the commercialisation of graphene, has entered into an exclusive development and supply agreement for the supply of Tantec Plasma Chambers. Lichfield based Dyne Technology Ltd. are the exclusive suppliers for the UK and Ireland for this revolutionary Plasma Treating technology.

Graphene is made from a layer of carbon one-atom thick yet is 200 times stronger than steel, has a higher electrical conductivity and is an excellent thermal conductor. However, despite Graphene’s desirable properties, implementing graphene sheets into industry applications can prove problematic.

Plasma Treating technology has allowed Haydale to help to solve the problems of using Graphene in practical industry applications by changing the materials functionality.

By working in close partnership with Tantec engineers, the Haydale team were able to share knowledge and expertise to create a patented process unique to Haydale using custom built Plasma Treating reactors.

Securing a contract with Haydale for the supply of plasma reactors has led to the installation of multiple systems all helping to increase Haydale’s surface treatment capacity. The new Tantec plasma reactors ensure that Haydale have a high degree of control over their manufacturing process while ensuring precision and consistency of treatment guaranteeing high performance.

Plasma Surface Modification to Change Material Functionality

Plasma Treatment of Graphene
Structure of Graphene courtesy of Wiki

Plasma Treating has allowed Haydale to create a unique plasma surface modification process which can meet customer demands for the increased functionalisation of graphene. Plasma Treating has ensured Haydale’s innovative process is capable of creating a wide range of surface modifications from bonding to repelling specific chemicals.

By teaming Haydale’s knowledge and expertise with our revolutionary Plasma Treating technology, a unique process has been created which adds value to graphene; The patented functionalisation process ensures consistent levels of treatment, can be tailored to meet the application required by the end user and has the flexibility to scale up volumes for future demand.

Plasma Treating technology has provided Haydale with an economic, efficient and effective method of supplying tailored solutions to enhance the functionality of graphene. To optimise the materials mechanical properties, good dispersion and the structural uniformity of nanoparticles is vital and Plasma Treating ensures this is achieved without damaging the material structure or adding environmentally damaging impurities.

eco_friendlyAlternative methods for functionalising graphene involve thermal and chemical shocking agents which, although offer flexibility in scale of production, can cause damage to the materials structure which can ultimately damage of the level of treatment achieved and result in defects with the final product.

Plasma Treating to change material functionality is an environmentally friendly process which removes the need for chemical agents and other environmentally damaging processes, which is not only beneficial for the environment, but has the potential to lower work place hazards and associated costs.

How is Plasma Functionalisation achieved?

Functionalisation is achieved through a low-pressure, low temperature Plasma Treatment process which achieves consistent and highly effective treatment on both mined and organic fine powder as well as other synthetically produced nanomaterial powders, producing high quality, few layered graphene’s and graphene nanoplatelets.

The Plasma Treatment process can functionalise with a wide range of chemical groups, with the level of functionalisation being tailored to the customer’s needs. Good dispersion improves the properties and performance of the host material and ensures the final product performs as specified.

Ray Gibbs, CEO at Haydale has commented on the “track record of performance” the custom built Tantec Plasma Treatment reactors have provided alongside being “confident in its engineering and build quality”.

Ray Gibbs continues, “These machines not only provide us with required capacity increase but a flexible operating capability to rapidly meet customer requirements. We also have a continual program of reactor developments to enhance the features and benefits of the machines which are expected to generate additional intellectual property to add to our existing “family” of patents.”

Plasma surface modification has opened a wealth of opportunity for Haydale’s unique process which transforms Graphene’s place within the composites industry. No longer is graphene effectively inert within manufacturing because of its poor dispersive and bonding qualities; the unique Plasma functionalisation process from UK based Dyne Technology Ltd. ensures consistent, high quality, environmentally friendly treatment while dramatically widening the scope of potential for Graphene to be used within practical industry applications.

Speak with an expert

Call us logoIf you’d like to speak to the UK and Ireland’s Number One supplier of Plasma Treatment, Dyne Technology, get in touch. You can call our technical engineers on +44(0) 1543 411 460 or email support@dynetechnology.co.uk.

Vacuum Plasma Surface Activation for Grupo Antolin

Grupo Antolin’s acquisition of Magna Interiors has formed one of the world’s largest players in the car interiors market. When they faced an adhesion problem whilst attempting to bond to the glass-filled polypropylene composite instrument panel developed for the Jaguar X260, they approached Lichfield based Dyne Technology Ltd. for a solution.

Traditionally “non-stick” materials widely used throughout automotive manufacturing, such as glass filled polypropylene, have low surface energy and as a result of this, achieving strong adhesion to these materials is at best difficult but often impossible.

Grupo Antolin’s engineers considered three key options for increasing the surface energy of the instrument panel i.e. Flame torch treatment, Primers and Plasma treating. Dyne Technology and Grupo Antolin worked in close partnership conducting a series of tests find the best solution for improving adhesion to these traditionally “non-stick” instrument panels.

Plasma surface activation offers an alternative to flame torch treatment

Education-and-ResearchFollowing rigorous testing, Flame torch treatment was eliminated due to the damage it was found to cause to the surface of the glass filled polypropylene’s surface, causing the polymer to shrink away from the glass fill fibres and allowing the fibres to grin through leading to poor adhesion results. Once the material’s surface has been damaged the strength and consistency of the bond that can be achieved is significantly reduced.

Primers were considered, however soon eliminated due their high cost and serious environmental impact.  Volatile chemical solvent based pre-treatments and primers were found to be expensive and difficult to apply to the complex 3 dimensional surface consistently. Removing volatile solvent based primers and pre-treatments from manufacturing brings great environmental benefits as well as bringing cost savings and a reduction of workplace hazards.

“The VacuTEC ensured consistent treatment of multiple components at once and has proved itself highly reliable. We are very impressed! Dyne Technology met the challenging prerequisite high standards of aftercare expected within the automotive industry. Working with Dyne Technology was an easy process, the team were extremely knowledgeable, efficient and provided great customer support.”– Spokesperson, Grupo Antolin

Grupo Antolin engineers concluded that Vacuum Plasma surface activation from Dyne Technology was the ideal surface activation process for their production needs because of its efficiency, economic viability, consistency of treatment provided and environmental benefits. Plasma eliminated the workplace hazards presented by Flame Torch treatment and Primer application as the Plasma stays safety controlled within the low pressure chamber environment. The low temperature plasma guarantees high quality, consistent bond strength without damaging the material’s surface.

 

Inside the VacuTEC Vacuum Plasma unit

Vacuum Plasma Surface ActivationVacuum Plasma provides a repeatable process, guaranteeing consistent results achieved whilst offering flexibility to perfectly fit within your manufacturing process. The Vacuum Plasma unit installed at Grupo Antolin the “Tantec VacuTEC”, is composed of a large vacuum plasma treatment chamber, the size of which was selected to suit the product size and production throughput required, in this case the chamber processes 4 compete instrument panel uppers (IP’s) at the same time. Whilst offering variable chamber sizes, all units share the same technology, parts and plasma generator, ensuring high reliability and a proven track record of excellent performance.

Vacuum Plasma Surface ActivationThe small footprint Plasma chamber can be mounted on wheels to allow easy relocation within the production facility and comes complete with its own vacuum pump. Easy to operate, the unit is equipped with easy “one button operation”, ensuring ease of use which in turn, has the potential to further optimise manufacturing.

The installation of the Dyne Technology “VacuTEC” Plasma surface activation unit has given Grupo Antolin the ability to take full control of their manufacturing process in-house. By taking the plasma surface activation process in-house, this eliminates the need to use external suppliers to treat parts prior to assembly which reduces costs and most importantly, ensures consistent treatment.

Speak with an expert

Call us logoPlasma Treatment provides a high performance, repeatable and safety critical method of surface treatment, if you’d like to speak to the UK and Ireland’s Number One supplier of Plasma Treatment, Dyne Technology, get in touch. You can call our technical engineers on +44(0) 1543 411 460 or email support@dynetechnology.co.uk.

Plasma Takes Aerospace Manufacturer’s Adhesion to New Heights

pdf downloadVacuum Plasma has provided an ideal solution for one of the world’s largest manufacturers of aircraft parts. The industry leading aviation and aerospace specialist first considered Plasma Treatment when facing difficulties bonding aluminium honeycomb to a polymer based outer layer.

Dyne Technology, the UK and Ireland’s Number One Plasma Treating equipment supplier, worked closely with the customer’s team of engineers during the research and development stages to develop an effective process to improve adhesion. Following several in depth trials and investigations at Dyne Technology’s Lichfield, Staffordshire based Technical Centre, it was determined that the super cleaning of aluminium honeycomb was vital to improve adhesion.

Vacuum Plasma unit
A VacuTEC unit supplied by Dyne Technology

Vacuum Plasma technology, the VacuTEC, was determined the most appropriate method of super cleaning the honeycomb aluminium prior to bonding due to the repeatability and consistency of results offered.

Ideal for safety critical processes, Vacuum Plasma offers a uniform and reproducible process, swift treatment times and ensures optimum adhesion properties for the honeycomb aluminium.  The VacuTEC is mounted on wheels to allow easy integration into the production facility and boasts plug and play technology to ensure simple set up.

How does Plasma Cleaning work?

Our incredible novel technology super cleans the surface of the material undergoing treatment which in turn increases the strength of bond that can be achieved.

Vacuum Plasma Treatment AerospacePlasma is created when a gas, in this instance and many others, compressed air, is subjected to a high energy discharge: the gas breaks up into electrons, ions, highly reactive free radicals, short wave UV light photons and other excited particles. When these species are excited by a high energy discharge, they effectively scrub the surface to be cleaned.

Ideal for complex geometry parts, such as honeycomb aluminium, the high energy discharge is able to effectively clean difficult to reach areas such as the individual cells of the aluminium honeycomb uniformly across the entirety of the part.

Trusted technology, bespoke chamber size

vacutec-tray
Example Chamber Size

The VacuTEC provides an easily repeatable process, utilising tried and tested Plasma technology that is proven to solve the problems of adhesion. The VacuTEC’s chamber size can be built bespoke to the customers’ needs; in this instance, the customer opted for a large chamber size with a 2000 litre capacity to fit their large components.

The installation of the VacuTEC has given our customer the ability to take control of their manufacturing process, ensuring that they have found a safety critical and repeatable method of surface cleaning they can rely on.

Speak to an expert!

Call us logoPlasma Treatment provides a high performance, repeatable and safety critical method of surface treatment, if you’d like to speak to the UK and Ireland’s Number One supplier of Plasma Treatment, Dyne Technology, get in touch. You can call our technical engineers on +44(0) 1543 411 460 or email info@dynetechnology.co.uk.

Plasma Treatment Upgrade for Leading Medical Device Manufacturer

Dyne Technology, the UK and Ireland’s Number One Plasma Treatment supplier,  has further added to their longstanding relationship with a pioneering medical device manufacturer.

First reaching out to Dyne Technology in 2011 when facing the problems of adhesion whilst developing and manufacturing a new medical device, the relationship has since continued to develop. Dyne Technology has gained trusted advisor status on solving the problems of adhesion, with employees attending Dyne Technology’s in-demand training course.  Following this, multiple laboratory sessions of testing to fully understand the adhesion problems faced by the customer and more importantly, find the appropriate solution.

Following rigorous testing, for the state-of-the art, high technology VacuTEC Vacuum Plasma unit was chosen to upgrade previous, smaller, lower technology plasma system within their research and development facilities.

Why Vacuum Plasma?

Vacuum Plasma Treatment

The VacuTEC provides an easily repeatable process, utilising tried and tested Plasma technology that is proven to solve the problems of adhesion. The VacuTEC’s chamber size can be built bespoke to the customers’ needs; in this instance, the customer opted for a large chamber size to increase production capabilities. The large vacuum chamber provides the perfect solution for treating a high volume of parts and has been designed with a fully integrated standard production jig. The production jig aids the treatment process, perfectly fitting within the multistep manufacturing process.

The unit has been designed to be slim-line and compact, reducing all-important floor space and comes with a fully integrated vacuum pump. The unit is mounted on wheels to allow easy integration into the production facility and boasts plug and play technology to ensure simple set up.

The installation of the VacuTEC has given enhanced ability to take control of their manufacturing process and further develop the leading medical components which they have become renowned for.

Could Vacuum Plasma benefit you?

Plasma surface activation removes the need for environmentally damaging chemical pre-treatments including solvent based primers and is environmentally friendly and clean room compatible.

Vacuum Plasma Treatment of Medical DevicesThe highly versatile VacuTEC with its large plasma chamber allows for the surface activation and surface cleaning of a wide variety of components across a large range of industries from automotive to aerospace, medical plastics to motorsport. Suitable for use on a wide use of materials, such as polymers, polyolefins, woven fibres, metals, rubber and more, Plasma Treatment is gaining increasing momentum throughout the UK and Ireland’s manufacturing industries.

Our cold Plasma Treating technology ensures that no damage is done to the treated component, including composite blends such as glass filled Polypropylene. If you are seeking a green alternative to harsh chemical solvents and high temperature flame treatments, plasma may provide the answer.

Call us logoCall us on +44(0) 1543 411 460 or e-mail support@dynetechnology.co.uk to find out more about our industry leading Plasma technology.

 

Corona Treatment of Glass Sheets Prior to Coating Application

A stand-alone Corona Treatment unit is the surface activation method of choice for a major European glass producer when seeking improved bond strength to glass sheets prior to a coating application.

The glass sheets undergoing treatment vary in size from 50mm to 1000m, as a result of this, the customer sought a flexible solution to ensure consistent treatment levels despite the parts varying in size.  Alongside this, a key customer demand was for a treatment system that did not damage the surface of the glass sheets during production.

Repeatable Surface Activation

Corona Treatment Coating ApplicationTo meet these key requirements, the stand- alone Corona Treatment unit is well equipped to ensure consistent treatment of the varying size glass panels which can be processed at a range of treatment speeds from 500mm per minute to 3000mm per minute.  The solution provided utilises a single high frequency wire electrode which is accurately positioned 2mm off the surface to be treated; this accurate positioning ensures no damage to the material’s surface while achieving optimal, consistent treatment levels.

Corona Treating Glass SheetsThe low maintenance, high performance treatment system is available for both single and double sided treatment, providing flexibility to fit your manufacturing process while ensuring optimal treatment levels.

To facilitate ease of installation at the customer site the standalone Corona Treatment unit was bench mounted to also ensure easy integration into the existing manufacturing process.

Stand-alone Corona Treatment unitThe unit comes equipped with an inbuilt conveyor for transporting the glass panels underneath the treatment head to ensure the unit operates at optimum treatment parameters and the required treatment speed is maintained; this easily repeatable process ensures a high quality, consistent and reliable level of treatment is achieved throughout the manufacturing process.

Could Plasma Treatment be for you?

Plasma surface treatment technology is an innovative and cost effective solution to the problem of adhesion and wetting in many industries.  Plasma surface activation and plasma cleaning are reliable, high performance methods of surface preparation prior to printing, bonding, painting, varnishing and coating processes.

Plasma treatment provides an economical solution for the cleaning and surface activation of “non-stick” polymers, composite blends, metals, ceramics and glass before further processing. Plasma Treating provides flexibility on parts undergoing treatment, being an effective, economical surface preparation method for sheet and web materials, complex geometry parts, extrusions and many more.

Call us logoIf you’d like to find out more, get in touch by calling us on +44(0) 1543 411 460 or emailing info@dynetechnology.co.uk.

Atmospheric Plasma Treatment of Solar Panels

Atmospheric Plasma Treatment of Solar Panels

The automated Plasma system designed for the customer’s requirement comes equipped with four adjustable plasma nozzles, however automated Plasma Treatment units can be equipped with single to multiple nozzles dependent on the customer’s unique manufacturing needs. The Plasma nozzles emit a relatively low temperature, potential free plasma discharge and are positioned a safe distance away from solar panels to ensure no damage to the material’s surface.

Repeatable process, consistent results

Automated Atmospheric Plasma TreatmentThe multi-nozzle treatment head is automatically traversed over the panel to be treated at a consistent speed to ensure the same standard of surface activation is achieved across all parts treated.
Equipped with a PLC central control unit, Plasma Treating met the customer’s’ requirements by offering reliable, accurate and easily repeatable levels of targeted surface treatment prior to bonding applications.
The automated unit offers a high degree of control over your manufacturing process
• The unit’s infeed and outfeed is easily automated or manual dependent upon your manufacturing needs
• The targeted treatment area can be as small as 6mm to as large as 2 metres
• Each nozzle is quickly and easily locally adjustable in horizontal and vertical directions

Could Plasma Treating be for you?

Plasma surface treatment technology is an innovative and cost effective solution to the problem of adhesion and wetting in many industries. Plasma surface activation and plasma cleaning are reliable, high performance methods of surface preparation prior to printing, bonding, painting, varnishing and coating processes.

Question ButtonPlasma treatment provides an economical solution for the cleaning and surface activation of “non-stick” polymers, composite blends, metals, ceramics and glass before further processing. Plasma Treating provides flexibility on parts undergoing treatment, being an effective, economical surface preparation method for sheet and web materials, complex geometry parts, extrusions and many more.

Talk to an expert!

Call us logoIf you’d like to find out more, get in touch and we’ll work together to find solution to meet your needs. To speak to Dyne Technology’s technical engineers, give us a call on +44(0) 1543 411 460 or email support@dynetechnology.co.uk.