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.

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.

Atmospheric Plasma Treatment for Brandon Medical Company

Atmospheric Plasma Improves Adhesion for Brandon Medical

Atmospheric Plasma Treatment has provided one easy solution for Brandon Medical Company. Brandon Medical are experts in the field of medical lighting design with over 40 years of healthcare experience. The Company manufactures and markets a range of medical lighting products from major operating theatre lamps through to bed head lamps.  Brandon Medical supply to the NHS (National Health Service), private hospitals, clinics and to primary care (family doctors) throughout the U.K. and Ireland.

DYNE logoWith Brandon Medical seeking to improve adhesion across a variety of components they produced, they contacted Dyne Technology, the trusted adviser for those looking for a solution to the problems of adhesion within the medical device manufacturing industry.

Solving the problems of adhesion

Seeking a highly efficient and cost effective solution to increase the surface energy of components to improve adhesion, the Brandon Medical team worked closely with Dyne Technology.

Question ButtonInitially, wide ranging discussions around the adhesion problems Brandon Medical were experiencing were held, after which, it was decided that a visit  to The Dyne Technology Centre in Lichfield was necessary to investigate the causes of the adhesion problems Brandon were experiencing.

An efficient, economic and flexible solution

Atmospheric Plasma TreatmentFollowing a series of tests it became clear that the surface needed to be both cleaned and activated to allow the coating to fully wet the surface and achieve the high level of adhesion required. From understanding Brandon Medical’s manufacturing process and the challenges they were facing, the surface treatment solution of choice was the PlasmaTEC Atmospheric Plasma Treatment unit.

The engineers at Dyne Technology developed a solution that met all three of these key criteria being economic, efficient and flexible. Employing a 3 axis Janome bench top robot equipped with a PlasmaTEC Atmospheric Plasma Treatment unit gave Brandon Medical the process control and flexibility required. The 3 axis bench top robot ensures accurate positioning of the Atmospheric Plasma Treatment nozzle throughout the entire surface treatment cycle, thereby guaranteeing a consistent plasma application. The cell is designed to allow the future integration of additional process equipment, giving the unit flexibility for any changes to Brandon Medical’s future manufacturing process.

“The knowledge and expertise of the Dyne Technology team was invaluable; they were totally committed to finding the ‘right solution for us at Brandon Medical. The production system installed has improved the adhesion of our coatings and therefore the overall quality, reliability and performance of our products.” – Nigel Davill, Technical Director – Brandon Medical

AP Extrusion 1The high efficiency Plasma Treatment is achieved by passing compressed air through a cylinder and nozzle assembly and subjecting it to a strong electrical field that ionises most of its atoms. The resulting super ionised air or what can also be referred to as Plasma is ejected through the nozzle tip and can be used for surface modification or surface cleaning.

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.

 

Robotic Atmospheric Plasma installed with Automotive Supplier

Atmospheric Plasma TreatmentDyne Technology Ltd are proud to have supplied Wipac Ltd, the world class design and manufacturing company who are renowned for their high technology exterior LED lighting headlamps and rear lamps for the world’s most prestigious car makers.

DYNE logoWipac faced the age old problems of adhesion when seeking to improve the adhesive bond of their rear lighting chrome plated plastic embellishers. Wipac required the production solution to be efficient, cost effective and highly flexible and sought advice from Dyne Technology, the trusted advisers for solving the problems of adhesion to a wide range of materials including polymers, EPDM and composite blends. The engineers at Dyne Technology developed a solution that met all three of these key criteria that would enable Wipac to treat the embellisher prior to application of a double sided adhesive tape prior to fixing it to the rear lighting cluster.

Repeatable, High Performance Plasma Treatment

Atmospheric Plasma TreatmentThe solution of choice is a robot mounted PlasmaTEC Atmospheric Plasma unit, also referred to as “air plasma”, giving Wipac the process control and flexibility they required. The robot ensures consistent and accurate positioning of the plasma nozzle throughout the complete surface treatment cycle, ensuring a consistent plasma application. The unit installed offers flexibility for future changes to manufacturing process, allowing easy integration of additional process equipment.

Dyne Technology has a successful partnership with a number of leading Robotic suppliers, this allows Dyne Technology to provide an exceptional package that is both functional and easy to integrate into new and existing production facilities.

“The Dyne Technology team were involved with us every step of the way, working closely with our manufacturing engineers during the initial trials, concept development and providing a cost effective and robust solution. The production system installed has improved the adhesion of our materials and therefore the overall quality, reliability and performance of our products.” – Dave Benton, Manufacturing Director – Wipac Ltd

How does the system work?

Question ButtonA typical Robotic Plasma Cell from Dyne Technology incorporates a multi axis robot that is easy to set up, offers a large screen programme system and has a fast ramp up time. The robot easily performs 3-dimensional linear and arc interpolations with positional repeatability of +- 0.01mm.  The dialogue based operating software ensures programming is simple, this eliminates complicated programming language for increased ease of use.

The robot is equipped with an Atmospheric  Plasma System which is powered from a generator which is located within the lower section of the cell. The robotic Plasma cell has been designed to be easy to operate alongside being simple to maintain with its compact design and small factory footprint. The robot mounted Atmospheric Plasma system supplied by Dyne Technology has proved to be a great success with Wipac Limited.

Are you having problems with adhesion?

Call us logoIf you’d like to find out more about innovative and cost-effective Plasma Treatment technology, get in touch with the Dyne Technology technical engineers on +44(0) 1543 411 460 or by emailing support@dynetechnology.co.uk.