Adhesion Promotion Using Flame Plasma

7/28/2019 Adhesion Promotion Using Flame Plasma

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Adhesion Promotion usingFlame Plasma

2009 SPE WebinarApril 22, 2009

Flynn Burner Corporation

New Rochelle, NY & Cleveland, OH


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Application in the Auto Industry

Painting - Bumper Fascias, Instrument

Panels, Fender Modules, etc.

Lamination of Polyurethane to polymer

based Fire Walls

Coating Window Moldings - Prevent

Squeaks


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Polymers in the Auto Industry


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Whats Flame plasma treatment ?


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Its NOT..


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If it s not magic, then what is

flame plasma treatment ???

It is


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Flame Plasma Treatment is

Using the reactive species in the

products of combustion (flame plasma)

to increase the surface energy of the

part


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Gas Combustion


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Reactive Species in the Flame

Plasma

(OH-) - Hydroxyl Free Radical

(COOH-) - Carbonyl & (O=C-O) - Carboxyl

(R-O-R) Ether & (R-C=O-OR) Ester

(O) + (O

-

) - Oxygen atoms & ions

(e- ) - Free electrons


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Whats adhesion promotion

all about ???

Its all about


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Bonding


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Comparison of Adhesion

Promotion Technologies

TECHNOLOGY ADVANTAGES DISADVANTAGES

Primers Good results Replacementcost,

Environmentalissues

DIRECT

FLAME

Easy to treat

complexshapes

Process

generates heat

DIRECT

FLAME

Cost effective -------


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Comparison of Adhesion


TECHNOLOGY ADVANTAGES DISADVANTAGES

Corona Cost effective Hard to treatcomplex shapes

Operators canget zapped

Atmosphericplasma

Treatscomplex

shapes better

than standard

corona

Cost & availabil ityof carrier gas

(He, Ar, N2)


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Flame & Corona Adhesion


POLARIZE the surface of the part by:

OXIDIZING the surface by addingfunctional groups aka LOMOMs

ALTERING the electron distribution &density AT THE SURFACE


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Effective Adhesion is Achieved

Surface Energy (part) - Surface Tension (paint)

>10 dynes/cm


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What is Surface Energy/Surface Tension

Liquid Surface Tension

Attractive forces between the molecules of

the liquid, i.e., the cohesive force

Solid Surface Energy

Attractive forces of the solid > cohesiveforces of the liquid


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How is Surface

Tension/Energy Measured ?

Dyne Pen/Solutiondynes/cm = 1milli-newton/m

Goniometercontact angle


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Wettability


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Surface Energy of Polymers(Plastics)

Polyethylene ~ 30-31 dynes/cm

Polypropylene ~ 29-31

TPE, TPU ~ 35-38

PET ~ 41-44


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Surface Tension of Liquids(coatings, paints, adhesives, inks, etc.)

Solvent based ~ 22 - 29 dynes/cm

Water based ~ 35 - 55


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Effective Adhesion is Achieved

Surface Energy (part) - Surface Tension (coating)

>10 dynes/cm


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Example

Surface Energy(part) - Surface Tension(coating)

{PP Water based coating}

30 dynes/cm 35 dynes/cm = (-5)

Will a good bond be achieved????


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Key Variables in Flame Treating

Flame chemistry

(air/gas ratio ~ excess O2)Flame geometry

Amount of plasma generated

Distance of the burner from the part


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Flame Chemistry

Optimum flame chemistry

0.1 0.5% O2 in the flame plasma(in the post combustion gases)


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Flame Chemistry


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Flame Chemistry


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Effect of temperature & humidity

on O2 in combustion air

TEMPERATURE

oC (oF)

Humidity (%) O2 (%)

16 (60 oF) 0 21

32 (90 oF) 100 20


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Gas composition from different

gas fields

COMPONENT Texas AlgeriaLNG

Alaska

Methane CH4 90 % 94% 99%

Ethane C3H6 5% 3% -----

Stoichiometricratio

10.5 10.7 9.98


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Flame Plasma Analyzer


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Flame Geometry & Amount of

Plasma Generated

Determined by:

Burner design

.Ribbon.Drilled port


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Flame Geometry

And.its critical because it affects

THE UNIFORMITY ofTREATMENT

(Laning/Striations)


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Burner Types

Ribbon Drilled Port


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RIBBON

FLYNN

RIBBON

PORTS A

B

DETAIL

END CAP

FLAME

SURFACE

2 PORT

RIBBON

PATTERN


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Drilled Port


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Aluminum Burner

(4) Port


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Flame Geometry Studies

0 speed

2 PORT 8 PORT


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Low

2 PORT 8 PORT


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High

2 PORT8 PORT


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Advantages of Ribbon vs. Drilled

Port Burner

RIBBON BURNER PROVIDES:

More Energy

(up to 200 kcal/mm/20,000BTU/In) without

striations

More Uniform Treatment


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Distance Burner to Part


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Distance - Burner to Part

Control System


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Control System

Zero Gas Pressure Regulator

Control System


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y

ZERO REGULATOR WITH PLASMA ANALYSIS

Control System


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y

MASS FLOW CONTROL

Control System


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Control System

MASS FLOW CONTROL WITH PLASMA TRIM


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Flame Color


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Flame Plasma-A Green Solution

No ozone produced

Low electrical power required

Clean burning

Low energy used

Low emissions of GHG ( CO2 )


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Flame Treatment-its about..


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Flame Treaters


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Flame Treaters


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Considerations for a Flame


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Considerations for a Flame

Treater

Control of flame chemistry 0.1 % - 0.5% excess O2

Burner selection Ribbon

Drilled Port

Distance 3/8

Control philosophy Zero Gas Pressure Regulator/ Venturi Mixer

Flame Plasma Analysis

Mass Flow + Flame Plasma Analysis


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Typical Webinar Attendee


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Adhesion Promotion

THANK YOU FOR

YOURATTENTION

&

ANYQUESTIONS??

Documents

Adhesion Promotion Using Flame Plasma