Topic: Openair plasma technology, running a plasma pre-treatment system

FAQ: Questions and Answers

What are the main advantages of the “Openair®“ plasma technology in comparison to other surface treatment methods?

The main advantage is the enormously high efficacy when compared to other methods for the activation of surfaces. Plasma systems are very easy to integrate into existing production lines, they are environmentally friendly, space-saving and also have low operating costs.

What will you need to run a plasma pre-treatment system?

Public current (230V/400V) as well as a compressed-air supply are sufficient. An extraction system is also required.

What are the possible production speed that can be reached?

The result of the treatment depends on the speed of the passing material, on the effective distance of the nozzle end, and on the width of the treatment area. Partially, processing speeds of up to 100 m/min can be reached. When treating EPDM-/ TPE sections, e.g., the speeds run are about 2 to 30 m/min.

Can original methods (use of solvents) be replaced by the “Openair®“ plasma technology?

Countless user operations have proven that their effectiveness concerning surface activation and cleaning will even be surpassed in practice. Additionally, the use of plasma technology makes it possible to completely abandon the use of environmentally damaging substances such as benzene or acetone.

Why is it that the technology works so well for composites?

Normally it is extremely difficult to pre-treat composites because of the differing electrical and thermal conductivities. In the “Openair®” plasma process, low temperature plasma flames are applied. Surface treating with this method has therefore no negative effects on composite materials.

Why is it so simple to integrate your plasma systems into production lines?

Plasma nozzles require very little space and are easily installed into existing production lines. We adapt our pre-treatment stations (plasma nozzles within a protective covering with extraction) to your individual manufacturing conditions.

What kind of running costs will arise?

The only operation expenses will result from the electricity and compressed-air consumption, and the ordinary maintenance costs. No costly operating supplies and consumables are needed.

Are plasma flames hot?

Plasma is much cooler than other combustion flames (about 300°C). With most applications, the temperature of the moving material increases by about 15 °C. Finger nails, for example, are also treated using the “Openair®” plasma method.

Does the plasma process produce any toxic emissions?

No ozone is released during the plasma pre-treatment. However, nitrogen oxides and monoxides can be produced when certain materials are pre-treated. An extraction system is to be provided because of health and safety reasons. Complete pre-treatment stations already contain the extractor components.

Are any special gases required for the “Openair®“ plasma process?

You need nothing else but electrical energy and oil-free compressed air. If you do not have a separate compressed-air supply, we can provide the systems with so-called low-pressure side channel compressors for you.

Is there any risk of an electric shock in the area of the plasma beam?

There is a risk to get an electric shock directly inside the plasma flame. The nozzles themselves are earthed and therefore floating, and can be directed by hand.

How long does the activation effect on the surface last?

To this question, no definite response can be given, since it varies greatly from material to material. The effect is strongest directly after the treatment, then fades gradually and settles at a higher level. Under ideal circumstances, the following production steps such as coating or painting should be carried out directly after the pre-treatment. Activation by “Openair®“ plasma shows an extreme long-time stability in comparison to other pre-treatment methods.

What is the distance between the nozzles and the surfaces being treated?

About 1 to 2 cm. The necessary adjustments are very simple, the use in the production process is uncomplicated. The components are not subject to mechanical wear and tear.

Is it possible to treat complicated or three-dimensional geometries?

The plasma flames infiltrate into grooves and small areas. The pre-treatment effect is even intensified in corners. Thus, you can pre-treat plane surfaces as well as complicated shapes.

Does the “Openair®“ plasma process alter the mass properties of a material?

This process is a surface treatment method where ions react with the material‘s surface. It does not change the mass in any way.

Does any scientific literature on the process exist yet?

The Fraunhofer-Institute in Bremen has attended to this subject. Relevant literature is available through us. Please send us an email if you require any further information.