Openair^® plasma coating solutions
Openair^® plasma can be used for two different coating applications. The first is to prepare surfaces so that coatings, including paint, lacquer and powder-coat, adhere more strongly and the resulting finish is higher quality. The second is to use the plasma jet to apply nanoscale-thin coatings that polymerize on the surface; a process we call PlasmaPlus^TM.

Openair^® plasma activates surfaces increasing their wettability, giving far superior coverage and achieving better aesthetics. As well, it increases bond strengths and so it improves functionality. At the same time it can reduce material costs.

Aside from surface activation for bonding, one of the main benefits of Openair¨ plasma has been to clean and functionalize surfaces, so priming is no longer required and parts can be painted and coated using solvent-free finishes. In this way productivity is increased along with dramatic reductions in environmental impact and health risks for employees.

How Openair^® plasma cleans and activates
Openair^® plasma neutralizes electrostatic charges and blasts off electrostatically attracted dust particles much better than de-ionized air blowers. It microcleans, eliminating organic and silicone based contaminants on the surface by blasting with high-energy ions and electrons. It activates the surface by introducing oxygen (mainly in form of carbonyl and hydroxyl groups). This increases surface energy and gives a more uniform flow and film formation as well as better adhesion.

• Reduce scrap rates in some cases by 90% through the combined effect of high and homogeneous wettability and dust removal.
• Improve the finish by minimizing dust particles, fish eyes, craters and bubbles in coatings.
• Reduce the amount of paint used by achieving a more consistent film build while reducing orange peel at the same time.
• Simplify the paint process, replace vacuuming, solvent wipe, de-ionized air gun operations, sanding, and in some cases the need to powerwash.
• Replace solvent-based paint systems with environmentally friendly water-based systems that can produce same or higher performance at reduced cost.
• Reliably paint and coat novel materials such as polypropylene and polyethylene with water-based paint systems.
• Increase scratch and chip resistance of painting or coating on plastic products like cellular phones, toys, window and doorframes, and automotive components.

Optimizing the different parameters
It is helpful to know the effect of every parameter that affects the activating process. In this way it is possible to get the best balance between improved quality, reduced costs and increased line speeds.

We have developed a test facility called A4-3001 to quantify the optimal nozzle distance and travel speed that produces the required level of activation for the material. On the supporting table, a sample of up to 8 1/2" x 11" size is evenly scanned by an XYZ unit. The system is connected to a personal computer that allows for precise control and recording of data. We would be pleased to work with your development engineers to optimize your production processes.

We can work with your development engineers to optimize the parameters for your production process.