Application of corona treatment and single coating in surface treatment
When the surface of the polymer is properly treated by corona, its wettability and adhesion can be changed, but the performance of the polymer matrix will not be affected. A typical processing device consists of a high-voltage electrode and an inverted ground electrode. The reverse-phase electrode is generally a roller and at the same time guides the object to be processed. After the applied voltage reaches the breakdown voltage of the air, the electrodes are discharged, generating atmospheric plasma. The insulating coating on the high-voltage electrode and / or reverse-phase electrode can maintain a smooth and uniform discharge and avoid conversion into a high-temperature arc.
The physical and chemical processes in the process of corona discharge are very complicated. The main reason is that the plasma induces various chemical reactions in the gas phase and on the surface of the polymer. Bonded to the polymer surface. These groups are polar, which improves the surface energy and ultimately improves the surface's adhesion to printing inks, paints, adhesives, and various other coatings.
Corona treatment system
Recently, SOFTAL launched a new CLN station specifically developed for narrow-format printing. This treatment system is a convenient plug-and-play type, including the treatment station itself, operating touch screen, easy-to-use generator and exhaust emission system. The treatment station was developed on the basis of the CLE series, which has been tested for a long time. The CLE series has been completely redesigned and optimized.
Softal's first multi-blade electrode
The solid structure and the anti-corrosion materials used make the product durable, and because of the new module structure, it is more convenient to maintain. Its compact cantilever structure makes it easy to install or retrofit into production equipment. The new CMB processing station for blown film production lines and the well-known CR station for ultra-wide format processing are corona treatment equipment developed for the blown film industry. They are based on the concept of module structure and have been optimized for various applications.
All SOFTAL corona processors are powered by the latest technology generators. The 7000 series is a new generation of corona generator. Its hardware and software are innovative products. The output power of the 7000 series is 1kW to 4kW. The output power of 6000 series single generator is 6kW to 50kW. High power can be obtained by integrating multiple generators. All 6000 and 7000 series generators have the famous configuration of SOFTAL products, such as CCP automatic speed and width dependent power control, SCT for runout processing, DCR and PROFIBUS and CAN bus interfaces for uniform corona processing at ultra-low power.
Reliability is the key
Reliable work under all environmental conditions is the key to economic production. Although modern general electromechanical technology can cope with harsh environmental conditions, the humid environment puts special requirements on the corona treatment system. If appropriate precautions are not taken, it may lead to unexpected high-cost shutdowns. For a long time, reliable operation in a humid environment has been an important advantage of SOFTAL equipment. The main factor for this success is the integration of both mechanical and electrical aspects, which has now become the standard configuration for most SOFTAL equipment. SOFTAL's solutions for humid environments have optional configurations for the upgrade of new systems and existing equipment, so that the equipment can be completely modified to adapt to the requirements of the environment. Available configurations for humid environments are SCS, CSF, HAS and HHV. SCS is a standard configuration of most SOFTAL corona generators. Combined with the special ceramics used in corona electrodes, SCS forms the basis for SOFTAL to work reliably in wet environments. The SCS can ensure that the corona treatment process can be started easily and reliably even if there is condensate on the high-pressure parts. Especially in the environment where the temperature and pressure drop from the outside to the inside, CSF can avoid the return of wet air condensation in the corona electrode when the device is turned off. Depending on the operating state, the CSF automatically controls the brake plates and exhaust fans in the exhaust system. In a very humid environment, and after the corona device has been shut down for a long time, a large amount of condensate will be generated on the static cold corona electrode during startup. HAS effectively eliminates condensation by raising the electrode temperature to the operating temperature before starting. HHV can ensure that even under very difficult production conditions, the parts with high voltage in the electrode are at a sufficiently high working temperature, thereby reliably avoiding the formation of condensate.
Similar to solutions for humid environments, SOFTAL provides first-class technology for all needs in the field of surface treatment, from drastically reducing corona electrode pollution, to rapid maintenance strategies, from non-standard material handling, to special engineering design and optimized combination of equipment Into the production line and process flow.
Corona treatment of panels and foam
The processing of polymer sheets and foam is a rapidly growing field. Due to the special shape of these products, especially the relatively large thickness, traditional corona treatment equipment cannot be used in many cases. Recently, SOFTAL has developed a new type of atmospheric plasma source, which is suitable for a variety of materials and structures that were previously unavailable for corona treatment equipment. The system has a compact structure, so it is easy to fit into the existing production line, and can be directly scaled up for a larger processing width, so that users can afford it. Compared with plasma spray systems, these plasma sources are extremely efficient and generally operate at a low power density of only 10W / cm². Handling large widths of a few meters is not only technically possible, but also economically feasible. In addition to being easy to adapt to new structures, one of the main uses of this new plasma source is to handle thick foam. For open-cell foam, no preferential discharge channels are generated, and for closed-cell foam, pinholes are not generated. Moreover, the device has low power requirements and can be used to process temperature-sensitive foams. In addition, the new system is particularly suitable for honeycomb structures and reinforcing materials.
Single layer coating
In many occasions in the printing and processing industry, it is necessary to use a tackifying primer. Softal and AirLiquide jointly developed Aldyne â„¢, a cost-effective, environmentally friendly, atmospheric pressure plasma process technology that replaces traditional liquid primers. Unlike the corona treatment where the plasma processing gas is ambient air, the Aldyne â„¢ process uses a gas with stable and well-controlled ingredients. In this way, the chemical reactions that occur in the plasma and the polymer surface can be controlled.
The resulting functionalized coating is only a single layer of molecular thickness, generally 0.3-0.4 nm. Since the AldyneTm process does not use any liquid or solid matter, it does not accumulate residues, thereby eliminating the costly cleaning process. Furthermore, in the AldyneTm process, no drying step is required, and there are no problems associated with the removal of organic solvents. The molecular coating can be adjusted according to the processing technology. For example, amido, imide, and amino groups can impart good adhesion properties to water-based, solvent-based, and UV-dried inks, paints, and adhesives. AldyneTm is an online technology that can be easily incorporated into existing production lines. Its main components are a specially designed plasma source (which can control the plasma gas at the ppm level), a gas delivery system and a complete automatic process control system.
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