Adhesion Promotion using Flame Plasma

2009 SPE Webinar April 22, 2009

Flynn Burner Corporation New Rochelle, NY & Cleveland, OH

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

Polymers in the Auto Industry

Whats Flame plasma treatment ?

Its NOT..

If its not magic, then what is flame plasma treatment ???

It is

Flame Plasma Treatment is

Using the reactive species in the products of combustion (flame plasma) to increase the surface energy of the part

Gas Combustion

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

Whats adhesion promotion all about ???

Its all about

Bonding

Comparison of Adhesion Promotion Technologies

TECHNOLOGY ADVANTAGES DISADVANTAGES Primers Good results Replacement cost, Environmental issues DIRECT Easy to treat Process FLAME complex generates heat shapes DIRECT FLAME Cost effective -------

Comparison of Adhesion Promotion Technologies

TECHNOLOGY ADVANTAGES DISADVANTAGES Corona Cost effective Hard to treat complex shapes Operators can get zapped Atmospheric plasma Treats complex shapes better than standard corona Cost & availability of carrier gas (He, Ar, N2)

Flame & Corona Adhesion Promotion Technologies

POLARIZE the surface of the part by: OXIDIZING the surface by adding functional groups aka LOMOMs ALTERING the electron distribution & density AT THE SURFACE

Effective Adhesion is Achieved

Surface Energy (part) - Surface Tension (paint)

>10 dynes/cm

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 forces of the liquid

> cohesive

How is Surface Tension/Energy Measured ?

Dyne Pen/Solution dynes/cm = 1milli-newton/m Goniometer contact angle

Wettability

Surface Energy of Polymers (Plastics)

Polyethylene ~ 30-31 dynes/cm Polypropylene ~ 29-31 TPE, TPU ~ 35-38 PET ~ 41-44

Surface Tension of Liquids

(coatings, paints, adhesives, inks, etc.)

Solvent based ~ 22 - 29 dynes/cm Water based ~ 35 - 55

Effective Adhesion is Achieved

Surface Energy (part) - Surface Tension (coating)

>10 dynes/cm

Example

Surface Energy(part) - Surface Tension(coating)

{PP Water based coating} 30 dynes/cm 35 dynes/cm = (-5) Will a good bond be achieved????

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

Flame Chemistry
Optimum flame chemistry

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

Flame Chemistry

Flame Chemistry

Effect of temperature & humidity on O2 in combustion air

TEMPERATURE

Humidity (%) 0 100

O2 (%) 21 20

(oF) 16 (60 oF) 32 (90 oF)

oC

Gas composition from different gas fields

COMPONENT Texas

Methane CH4 90 % Ethane C3H6 5% Stoichiometric 10.5 ratio

Algeria LNG 94% 3% 10.7

Alaska 99% ----9.98

Flame Plasma Analyzer

Flame Plasma Analyzer

Flame Plasma Analyzer

Flame Geometry & Amount of Plasma Generated Determined by:

Burner design .Ribbon .Drilled port

Flame Geometry
And.its critical because it affects THE UNIFORMITY of TREATMENT (Laning/Striations)

Burner Types
Ribbon Drilled Port

RIBBON
2 PORT RIBBON PATTERN

DETAIL

FLA ME SURFA CE END CAP

B FLY NN RIBBON PORTS A

Drilled Port

Aluminum Burner (4) Port

Flame Geometry Studies

0 speed

PORT

PORT

Flame Geometry Studies

Low

PORT

PORT

Flame Geometry Studies

High

PORT

PORT

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

Distance Burner to Part

Distance - Burner to Part

Control System Zero Gas Pressure Regulator

Control System
ZERO REGULATOR WITH PLASMA ANALYSIS

Control System
MASS FLOW CONTROL

Control System
MASS FLOW CONTROL WITH PLASMA TRIM

Flame Color

Flame Plasma-A Green Solution

No ozone produced Low electrical power required Clean burning Low energy used Low emissions of GHG ( CO2 )

Flame Treatment-its about..

Flame Treaters

Flame Treaters

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

Typical Webinar Attendee

Adhesion Promotion
THANK YOU FOR YOUR ATTENTION & ANY QUESTIONS??