Industrial Plasma Pretreatment with Plasmatreat

Surface modification through plasma treatment, which enhances material properties across various surfaces, has long captivated the interest of many industries. Today, cutting-edge processes ensure precise control over plasma generation and application, facilitating reproducible results. This capability enables extensive surface cleaning through direct plasma action and allows for structural modifications that enhance desired material properties. Users benefit from a wide array of available plasma processes:

Vacuum or low-pressure plasma – Holistic treatment in a batch process

One well-established plasma process for the industrial pretreatment of components is vacuum or low-pressure plasma. This process utilizes electromagnetic high-frequency fields to generate plasma between two electrodes. The plasma is produced within sealed chambers under vacuum conditions, typically ranging from 10⁻³ to 10⁻⁹ bar.

For this process, the components are treated in a separate pressure chamber, isolated from the production line. Within the vacuum chamber, gases or gas mixtures are ionized through the application of electromagnetic fields, transforming them into a highly reactive plasma state.

The surface properties of the treated components can be precisely tailored by selecting the appropriate gas composition (such as air, nitrogen, or oxygen) and the energy coupling method, which may involve DC, kHz, MHz, or GHz frequencies.

In the low-pressure plasma process, components are treated across a large surface area. However, a waiting period is required before further processing can occur, making the procedure relatively time-intensive. This is particularly challenging for the industrial treatment of substrates in large quantities.

 

Overview of Low-pressure Plasma Systems

Atmospheric plasma solutions – High-efficiency plasma cleaning, activation and nanocoating

Atmospheric-pressure plasma pretreatment is one of the most efficient methods for cleaning, activating, or coating a wide range of materials, including plastics, metals (e.g., aluminum), glass, recycled materials, and composites.

Unlike low-pressure plasma technology, Openair-Plasma® technology operates without the need for a dedicated chamber system. This is possible because Openair-Plasma® leverages advanced surface modification techniques under atmospheric pressure conditions.

This unique capability allows the technology to be seamlessly integrated into production lines, even with robotic controls, at a low cost. The versatility of Openair-Plasma® makes it a vital technology for innovative surface pretreatment applications.

Atmospheric-pressure plasma treatment is particularly cost-effective and serves as a popular alternative to low-pressure plasma and corona processes.

 

Overview of atmospheric pressure plasma systems

 

The high intensity of Openair-Plasma® treatment makes it possible to significantly streamline the entire process.

Dr. Frank Kukla, Business Manager, CeraCon GmbH

Openair-Plasma® - Inline integrated for a targeted, selective treatment

Atmospheric plasma is generated at normal pressure, eliminating the need for low-pressure chambers. Thanks to Plasmatreat's patented Openair-Plasma® nozzle technology, it is now possible to integrate an efficient, gentle, and potential-free plasma process directly into manufacturing workflows. This inline capability allows for seamless integration into existing production lines.

Openair-Plasma® utilizes compressed air to modify the surface properties of treated materials. To achieve this, Plasmatreat has developed specialized nozzles that deliver the plasma jet with pinpoint accuracy to the substrate. The nozzle heads and process parameters, such as plasma jet intensity and application distance, are precisely tailored to each application. Site-specific factors, such as component transport speed, are also carefully considered—one of Plasmatreat’s key strengths.

This cutting-edge plasma technology is versatile, suitable for all surface types, and achieves microfine cleaning as well as high activation of substrates.

 

Openair-Plasma® systems for various application processes

Learn more about plasma surface treatment

Plasma cleaning

Microfine cleaning with plasma can remove the smallest dust particles from the substrate. Precisely defined surfaces with the best prerequisites for further processing are created thanks to the chemical-physical reaction in the nano range.

Surface activation

Pretreating different plastics with plasma can also change their surface properties. When in contact with plasma, the mostly non-polar plastics acquire oxygen- and nitrogen-containing groups.

Reduction

In oxide reduction, plasma breaks down and eliminates oxide layers from metal surfaces without chemicals, ensuring better conductivity and bonding for applications in electronics, automotive, and renewable energy industries.

Plasma coating

Another field of application for plasma technology is the production of ultra-thin coatings on surfaces. An organo-silicon compound is added to the plasma as a precursor and deposited on the material surface.

FEATURES &
ADVANTAGES

 

Openair-Plasma® technology compared to other pretreatment processes

  • High process reliability: Openair-Plasma® technology is distinguished by high fail-safety and process reliability.
  • High cost-effectiveness: High process speed, even in multi-shift operation, and lower scrap rates provide high process efficiency. Because it allows for flexible material selection, the Openair-Plasma® process also facilitates the use of more advantageous materials.
  • High degree of activation: Unlike corona treatment, Openair-Plasma® permits a high degree of activation of the surfaces to be treated.
  • Large process window: Openair-Plasma® permits a large process window: The danger of thermal component damage is extremely low in comparison to flaming.
  • Easy to integrate: In contrast to mechanical processes, like roughening and sand or aluminum oxide blasting, Openair-Plasma® can easily be integrated inline in existing processes.
  • Environmentally friendly: The Openair-Plasma® process makes it possible to treat surfaces with solvent-free and VOC-free methods. Unlike electrochemical processes, such as galvanizing or galvanically-supported pickling and chrome plating, wet chemistry is not required.

Interesting Applications for Surface Modifications

Surface Activation

Pretreating different plastics with plasma can also change their surface properties. When in contact with plasma, the mostly non-polar plastics acquire oxygen- and nitrogen-containing groups.

Plasma Coating

Another field of application for plasma technology is the production of ultra-thin coatings on surfaces. An organo-silicon compound is added to the plasma as a precursor and deposited on the material surface.

Plasma Cleaning

Microfine cleaning with plasma can remove the smallest dust particles from the substrate. Precisely defined surfaces with the best prerequisites for further processing are created thanks to the chemical-physical reaction in the nano range.

Plasma Reduction

Oxide layers on metal surfaces can pose challenges in processes like soldering and bonding. The REDOX®-Tool, an innovation within the Openair-Plasma® suite, offers an inline solution for oxide reduction. By utilizing atmospheric pressure plasma, this tool efficiently reduces metal oxides, eliminating the need for traditional fluxes and enabling flux-free soldering processes.

Typical Processes for the Use of Atmospheric Pressure Plasma

Bonding

Adhesion improvement for secure, durable bonding of plastics and metals

Printing

Optimal printing and ink bonding and highest print quality

Painting

Openair-Plasma® provides for optimal paint adhesion

2-K Injection Molding

Plasma treatment for secure, long-term adhesive bonding of plastics and metals

Learn More About Plasma Surface Treatment

Surface Activation

Plasma Coating

Plasma Cleaning

Plasma Reduction

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