Tag Archives: corona treatment
Of all the challenges manufacturers face, creating and optimizing critical surface processes for various materials can be very difficult. Traits such as location, size, shape, and texture can add to the challenge. The success of any critical surface process requires an in-line, fast, easy, and accurate verification method.
That’s why more and more manufacturers are turning to the Surface Analyst. Whether it’s bonding, painting, printing, cleaning, coating, or sealing, BTG Labs’ Surface Analyst optimizes critical surface processes and monitors surface treatment on virtually any surface so the product is guaranteed to deliver.
BTG Labs engineered the Surface Analyst to adapt to any application directly on the factory floor. Patented Ballistic Deposition deposits a stream of micro-droplets on the surface; these micro-droplets contain kinetic energy which allows the drops to overcome various textures and different angles without interfering with measurement accuracy. The drop size can also be adjusted so that measurements can be taken on any sized surface from a giant wind turbine to a minuscule medical catheter.
Contrary to popular belief, print isn’t dead: at least not printed packaging, an industry growing to a worth of $8 billion of the $20 billion global print market.
The printed packaging market is booming. As with any growing industry, manufacturers must work vigorously to produce the best product and continue developing better ones.
Some of the newer developments include smarter surface processes. Que BTG Labs. When it comes to surface processes, we’re in our element. As experts in materials science, we have the ability to optimize critical surface processes for manufacturers—including printed packaging.
Any printing involves critical surface processes including supplier quality check, surface treatment, verification, shelf life, and trouble shooting.
The Surface Analyst improves these areas of printed packaging. This surface cleanliness gauge determines the quality of incoming product; sets or optimizes specifications; verifies surface treatments such as corona and flame; determines the shelf life of the material after treatment; and trouble shoots printing issues.
Plastics manufacturers are all too familiar with the challenges of bonding thermoplastics. Last week, BTG Labs successfully hosted a webinar with Plastics Technology to discuss improving bonding of thermoplastics. The webinar, entitled “Understanding Surface Energy: How to Measure and Control the Surface Properties of Thermoplastics to Maximize Adhesion,” brought in almost 400 registrants.
Presented byBTG Labs’ Chief Scientist Dr. Giles Dillingham who discussed the surface characteristics of thermoplastics. Dr. Dillingham also explored surface treatment processes such as flame, corona, and plasma, and ways to monitor and verify those processes. The ability to understand and measure the surface precisely is the key to successfully bonding thermoplastics.
Every plastics manufacturer knows that bonding low energy thermoplastics can be challenging. In the upcoming webinar hosted by Plastics Technology, BTG Labs’ Chief Scientist Dr. Giles Dillingham will discuss practical ways to improve bonding of thermoplastics more reliably and efficiently.
Dr. Dillingham will discuss the nature of thermoplastic surfaces and how the manipulation of various surface treatment processes—flame, corona, and plasma—make or break a surface. The webinar will discuss how the Surface Analyst uses water contact angle measurements to lend imperative insight into surface energy and in turn, hone in on the necessary treatment level for a higher quality, more consistent manufacturing process. After all, the most expensive surface treatment is nothing without an in-place monitoring process. …Read More
Manufacturers often encounter a similar puzzle, when cleaning invisible contaminants from a surface, how do you know when the surface is clean; how clean is clean enough? This is a common question that manufacturers ask when preparing their surfaces for bonding, coating, sealing, printing or painting. Until now, there hasn’t been an objective and reliable way to answer this question. Successfully cleaning a surface directly correlates to the adhesive ability of the surface. In order to get something to stick reliably the surface must be clean. How we define that parameter is different for a variety of materials.
For example, you clean your car differently than you clean your dishes. Why? Because a car rides on the road through rain, smog, dirt, maybe mud, and the other is a vehicle for your food.
At BTG Labs, our answer to the “clean enough” question is, “Depends on what you’re doing.” There are dozens of critical surface preparation processes that exist for a number of different applications. A handful include:
- Flame treatment on polypropylene bumpers prior to painting
- Plasma treatment on PET catheters prior to coating
- Hand sanding and solvent wiping on aircraft nut plates before adhesively bonding to composite
- Grit-blasting titanium golf clubs in preparation of bonding to composite
- Corona treatment on film for packaging prior to metallization, lamination, or coating
It’s Opening Day in Cincinnati, Ohio! Now this isn’t just any season opener, Opening Day in Cincinnati is an unofficial city holiday. Downtown is painted red as people gather for the 98th Opening Day Parade and celebrations around town. Offices slow down and desks are empty in schools. Today, Cincinnatians are gearing up for the hometown Reds’ game against the Phillies. We don our red, grab our game day snacks, and pray for fair weather.
Buy me some peanuts and cracker jacks
Manufacturers working with metal and worrying about metal performance are all too familiar with the obstacles that come along with coating, painting, bonding, printing, or sealing it. While the uses of metal in manufacturing are countless and exist in numerous industries, the common denominator is ensuring the appropriate surface cleanliness prior to surface critical processes to guarantee successful adhesion. Common surface cleanliness gauges—dyne inks and water break—are subjective and do not offer quantitative results. Water break can be messy and time consuming and dyne is destructive to the part and dangerous to the user. While these methods can offer some insight into surface cleanliness, they are less than ideal.
BTG Labs Surface Analyst is a fast, easy, accurate, and non-destructive surface cleanliness gauge that tells the user right on the manufacturing floor how prepared the surface is to bond. This hand-held instrument improves surface processes and guarantees a bond will stick. Numerous manufacturers in industries such as consumer goods, automotive, and aerospace, have implemented the Surface Analyst in their specifications to improve their critical metal surface processes. …Read More
conPolymers are some of the most common base materials used in automotive parts. Polypropelenes, Polyolefins, and ABS plastics are used in dashboards, door panels, bumper fascias, liftgates, sensors, and increasingly exterior doors and fenders. A polymer is a low surface energy material that typically needs some form of surface processing prior to bonding an assembly, encapsulating a sensor, painting an interior control knob or an exterior bumper fascia. These materials also tend to show high contamination with mold releases that can be tough to remove and will essentially guarantee unsuccessful adhesion or coating.
There are a variety of surface processing methods used in the industry to help remove contamination and increase the surface energy of these polymer materials. These processes include flame treatment, plasma treatment, corona treatment, and solvent wiping. Another option is to utilize specialty paints and adhesives that tolerate lower energy substrates. There are pitfalls, however, to implementing any of these methods that manufacturers need to be aware of. Understanding the nature of these surface-critical systems is the only way to guarantee success in the final result. Control of the inputs means predictability and control of the output.
Fluid Deposition Style of Contact Angle Measurements
Measuring the contact angle of a fluid on a surface provides an accurate reading of surface energy. However, methods of depositing the droplet and measuring the contact angle vary. With this sensitive process, every detail and particularity effects the measurement.
Common surface measurement instruments, such as goniometers, use an automated syringe needle to deposit a single drop of fluid. However, the manner in which the drop of fluid is deposited greatly impacts the contact angle and entails precise control. Furthermore, the composition of fluid used effects the measurement and potentially the surface.
Alternative fluids can be dangerous to the user and contamination to the material. This often requires the use of a coupon, or sample rather than a measurement on the actual surface of the material in question. Furthermore, a single drop does not have the ability to measure on diverse surfaces.
Higher Performance Materials Call for Higher Demand of Quality
In the automotive industry, there is a constant focus on higher performance materials that provide more with less — better strength, better fuel economy, and better durability at the expense of weight and cost.
What manufacturers once produced in steel and iron they now make in aluminum. Furthermore, manufacturers are increasingly replacing aluminum with composite. Whether it is a car roof, hood, trunk lid, intake manifold, or dashboard, automotive manufacturers are pushing the boundaries of what they thought was possible for material performance.
New materials require new coatings, new adhesives, and new paints. And all of these require new process solutions to guarantee an ever-increasing demand of quality.
A major challenge has been the need to shift to a higher performance material that requires bonding, coating, sealing, painting, or printing. These materials often have more stringent processing specifications to get similar adhesive performance. …Read More