Surface Activator B is a printing surface activator accessory that improves ink adhesion in all decoration processes. The treated materials maintain much better resistance characteristics over time compared to untreated materials. The treatment is temporary and therefore the processes must be defined within 12 or 24 hours.
Surface Activator, the new machine being presented, is certainly a solution that looks to the future with the awareness of someone who has a great knowledge of materials and surfaces.
The newly developed plasma generator on board this flatbed enables any surface to be activated and thus made wet or wettable. This also translates into printability of difficult substrates and surfaces such as polypropylene (PP) polyethylene (PE) polyamide (PA) polycarbonate (PC) glass metals and leather.
The rotary head has the option of different tips depending on the type of treatment required, speed requirements and size, and the tips are supplied and customised according to requirements.
The non-invasive pre-press treatment, unlike treatments such as corona discharge or flaming, allows the surface to be perfectly activated in a short time and therefore receptive to inks and post-treatments. The format of this type of flatbed is customisable and therefore the customer can request a personalised configuration according to his needs.
Secure adhesion without the use of primer
Recycled plastics and wood-plastic composites are almost always characterised by difficult-to-bond surfaces, which in the past made them almost impossible to use for industrial processes. A new in-line plasma system is considered revolutionary in the search for a cost-effective solution for the production of composite panels.
The rotating nozzle method now makes it possible for the first time to pre-treat large, lightweight panels with potential-free atmospheric pressure plasma at high speeds and in a continuous process. Bionics provided the inspiration for the production of modern plastic panels right from the initial development.
Nature provided the example for the honeycomb structure, plastic technology provided the polypropylene (PP). Honeycomb panels are increasingly used as the primary layer in lightweight composite panels because they are generally waterproof and offer high strength and stiffness.
The most important feature, however, is undoubtedly the low weight. However, the new panel technology is able to reach its full potential if parts can be produced in an efficient, cost-effective and environmentally friendly manner.
Until now, the pre-treatment of PP or PVC composite panels has mainly been carried out by wet chemical methods with the help of primers containing solvents, which are harmful to both humans and the environment due to high VOC emissions. Primers are generally applied by hand to the primary layer by spraying or laminating.
Irregularities are inevitable because it is very difficult to achieve a uniform application with this method. An additional problem is the need to observe the temperature of the material being treated very precisely when using primers. Basically, it would be possible to use water-dispersed adhesive primers without solvents, but they require much more energy during processing.
The fourth state of matter
Plasma technology makes use of another natural phenomenon, creating technical plasmas that mimic natural discharges in the atmosphere. Plasma is based on a simple physical principle. Plasma technology uses another natural phenomenon, creating technical plasmas that mimic natural discharges in the atmosphere. As more energy is added to the gas, it becomes
As more energy is added to the gas, it becomes ionised, i.e. the electrons gain more kinetic energy and leave the atomic structure.
This generates free electrons, ions and molecular fragments, transforming the gas into plasma - also known as 'the fourth state of matter'. In the past, however, this state of matter was usable at atmospheric pressure in a very limited way due to its instability.
This technology, which is used today in industrial applications all over the world, is characterised by a triple action: the plasma activates the surfaces with controlled oxidation processes, thus increasing the surface energy and at the same time discharging the surfaces. At the same time, the plasma has a micro-fine cleaning effect on the surfaces of materials such as metals, plastics, ceramics and glass.
The dual effect of intense activation and simultaneous micro-cleaning significantly exceeds the effectiveness of conventional systems. The result is a homogeneous paint finish and stable, long-term adhesion of the coating, even under the most difficult conditions of use.
Activation
L’energia di superficie è l’indice di misura più importante per valutare l’adesione prevista di uno strato adesivo su un rivestimento di protezione. In generale, le plastiche hanno un’energia di superficie bassa, generalmente tra < 28 mJ/m² e 40 mJ/m²; troppo bassa per una buona adesione. Con l’attivazione al plasma, l’energia di superficie può essere aumentata notevolmente.
Openair plasma technology also enables energy values of > 72 mJ/m2 to be achieved. This not only dramatically improves surface wettability but also enables the reliable adhesion of previously incompatible substrates, for example water-based adhesives or coating systems for difficult surfaces such as apolar plastics. The typical temperature rise during plastic treatment is less than 30 °C.
Thanks to the special design of the nozzle, the treatment space on the surface of the substrate remains practically electrically neutral, thus enabling even very sensitive electronic components to be activated.
Electrostatic charges
In technical terminology, the plasma state is defined as an electrically conductive gas. When the low-potential plasma beam strikes the surface, the electrostatic charges on the surface are dissipated to the ground, i.e. the electrostatically charged surfaces of the material are completely neutralised.
This prevents a plasma-treated plastic component from attracting pollutants from the air around it during the manufacturing process; it can be coated or bonded immediately.
Micro - cleaning
By using atmospheric plasma technology instead of traditional processes, processes such as the removal of surface dust, release agents or additives from polymer materials have been decisively rationalised. The metals subjected to plasma treatment are also subjected to micro-cleaning. During this process, organic pollutants such as fats and oils are vaporized, fragmented and partially oxidized and transformed into carbon dioxide and water.
