TECHNOLOGY
TECHNOLOGY The plasma process is used to optimally prepare material surfaces before processes such as gluing, soldering, bonding, wire-bonding, injection molding, potting, coating, printing or any other process that requires a clean surface and sufficient surface energy to create a durable adhesion. The bdtronic plasma systems offers the up to date pretreatment method for long-term stable bond strength, free of residues, clean and polar surfaces. Laborious pre-treatments such as chemical cleaning and use of primers can be avoided, resulting in cost savings and a better environment protection.
APPLICATIONS Before Potting/Vacuum potting Before Sealing, gluing or printing Before Spraying, coating or painting - Fan controllers - Sensors Before Applying thermally conductive pastes - Engine control units - Cured-in-place gaskets - Sealing of enclosures Before Bonding - Truckloading ramp lights - Door handles - PCBs Before Foaming - Filters - Foamed gasket for car windows
BASIC PRINCIPLE What is plasma? - 4th state of matter - Partially ionized gas (ions + electrons) - Physical pretreatment method - 99.9% of the universe - Gas plasma artificially generated by electric field Benefits - Long-term stable bond & highest strength - Residues-free surface - Improved adhesion - Reliable gluing process - Long-term durable joint - 100% tight sealing How does plasma work? - Electron and ion bombardment - Cracking and blasting away of carbon hydrides - Breakage of atomic bindings on surface - Changing intermolecular forces - Surface reaction with oxygen or OH- - Increasing the surface energy (polarity) Features - Continuous process - Process monitoring - Option for traceability
PROCESS Durable adhesion, free of residues, clean and polar surfaces! Cleaning Passivation Hydrophilization - Ultrafine cleaning - Removing organic contaminations - Removing the separation layer - Controlled homogenous oxidation of surface - Increasing the surface roughness (nm) - Decreasing the surface roughness depth (nm) Activation Reduction Functionalization - Increasing surface tension - Improving adhesion - Removal of (inhomogeneous) oxide layer - Special process gas (forming gas) required - Creating e.g. OHgroups on surface - Increasing concentration of O- on the surface - Improving wettability
PROCESS DIMENSIONING Contact angle measurement - Exact method to determine the surface tension Use of test ink - Simplified method to determine the surface tension Required surface energy - Base products Greater than 38 m/n to print with solvent-based varnish Greater than 42 m/n to bond with solvent-based glues Greater than 45 m/n to print with water-based varnish
PRINCIPLES 1. Atmospheric plasma BPS300 BPS1000 2. Low pressure plasma BPS-LP Advantages - Space-saving - Potential-free plasma - User friendly - Suitable for electronics and thermal sensible parts - Inline compatible - Cost effective Advantages - Potential-free, particle-free low pressure plasma - Cold plasma - No static charging - Suitable for electronics and thermal sensible parts - Inline compatible or batch plant - Modular construction
1. ATMOSPHERIC PRESSURE Advantages - Environmentally friendly - User friendly - Ozone-free - Cost effective - Contact free - Inline compatible - Space saving - Potential free (suitable for electronics) - Continuous process control Features - Suitable for electronics - High availability - Integration in continuous line production - Variants for all typical plasma applications Process monitoring and analysis - Of all relevant process parameters - Wear
1. ATMOSPHERIC PRESSURE Body with tube connection Optical ignition control/gas flow control Handle Tube package Plasma generator Plasma head with integrated electrode Plasma nozzle
1. ATMOSPHERIC PRESSURE BPS300 Features - Standard device (300W) - Adapted to dispensing process - Suitable for thermoplastics and metal - Light-weight and space saving - Low temperature - Plug&Play - Extended nozzle Options - PROFIBUS/PROFINET - All process data available for traceability - Remote maintenance - Twin-head device
1. ATMOSPHERIC PRESSURE BPS1000 Features - High power device ( 1000W) - High process speed - Suitable for electronics - Wide range of settings - Air pressure - Plasma ignition Options - Large variety of nozzle variants - PROFIBUS/PROFINET - All process data available for traceability - Remote maintenance - Twin-head device - Large width nozzle (rotating nozzle) - Potential-free nozzle
1. ATMOSPHERIC PRESSURE BPS1000 VISUALIZATION Settings: frequency, override, gas flow rate, gas pressure, current and voltage
1. ATMOSPHERIC PRESSURE BPS1000 VISUALIZATION Process monitoring: wear, operating hours, settings, gas pressure and plasma ignition
2. LOW PRESSURE Advantages - Environmentally friendly - User friendly - Ozone-free - Cost effective - Contact free - Inline compatible - Space saving - Potential free (suitable for electronics) - Continuous process control Features - Low temperature plasma - Integration into production lines (cycle) with assembly belt - Suitable for typical transport & product carrier systems - 40kHz plasma generator - 2x process gas supply - Modular design with configurable Plasma chamber size Pump power
2. LOW PRESSURE VISUALIZATION Process control: gas flow rates, pressure control, action list, action symbolic
2. LOW PRESSURE VISUALIZATION Process monitoring: gas flow rates, pressure, plasma ignition
PROCESS CONTROL Gas flow monitoring Hour meter Power User level management Remote maintenance
STANDARD MACHINES Table top Manual/integration plasma machine for individual part processing with manual load and unload Integration unit Incl. cabinet, touch panel and digital handshake/profibus B2000-P Integration plasma machine for small batch production with program change and manual load and unload B5100-P/5200-P Fully automated plasma machines for high production rates and fully automated part handling B5600-P Fully automated plasma machine with augmented traversing range BPS-LP Low pressure plasma machine with full process control and integrated PLC
REFERENCE PROJECT Product description & usage/function/information: Cleaning and activation of plastic (PBT GF30) and aluminum (sheet, die cast) housing and lid (tongue and groove) prior to dispensing of a sealing/adhesive and leakage-free lid attachment for the automotive industry Project description: - Two processes in one machine - Less invest - Less floor space - Only a single XYZ system required to move both heads Process: Combined integration of plasma and dispensing
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