TECHNOLOGY

PLASMA

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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 pre-

treatment 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.

PLASMA

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PLASMA

APPLICATIONS

Before

Potting/Vacuum

potting

- Fan controllers

- Sensors

Before

Applying thermally

conductive pastes

- Engine control

units

Before

Sealing, gluing or

printing

- Cured-in-place

gaskets

- Sealing of

enclosures

Before

Bonding

- Truckloading ramp

lights

- Door handles

Before

Spraying, coating

or painting

- PCBs

Before

Foaming

- Filters

- Foamed gasket for

car windows

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PLASMA

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

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)

Benefits

- Long-term stable bond & highest strength

- Residues-free surface

- Improved adhesion

- Reliable gluing process

- Long-term durable joint

- 100% tight sealing

Features

- Continuous process

- Process monitoring

- Option for traceability

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PLASMA

PROCESS

Cleaning

- Ultrafine cleaning

- Removing organic

contaminations

- Removing the

separation layer

Activation

- Increasing surface

tension

- Improving adhesion

Passivation

- Controlled

homogenous

oxidation of surface

Reduction

- Removal of

(inhomogeneous)

oxide layer

- Special process gas

(forming gas)

required

Hydrophilization

- Increasing the

surface roughness

(nm)

- Decreasing the

surface roughness

depth (nm)

Functionalization

- Creating e.g. OH-

groups on surface

- Increasing

concentration of O-

on the surface

- Improving wettability

Durable adhesion, free of residues, clean and polar surfaces!

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PLASMA

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

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PLASMA

PRINCIPLES

1. Atmospheric plasma

• BPS300

• BPS1000

Advantages

- Space-saving

- Potential-free plasma

- User friendly

- Suitable for electronics and thermal sensible parts

- Inline compatible

- Cost effective

2. Low pressure plasma

• BPS-LP

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

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PLASMA

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 PLASMA

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PLASMA

1. ATMOSPHERIC PRESSURE PLASMA

Plasma

nozzle

Optical

ignition

control/gas

flow control

Plasma generator

Plasma

head with

integrated

electrode

Handle

Body with tube

connection

Tube package

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1. ATMOSPHERIC PRESSURE PLASMA

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

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1. ATMOSPHERIC PRESSURE PLASMA

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

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1. ATMOSPHERIC PRESSURE PLASMA BPS1000

VISUALIZATION

Settings: frequency, override, gas flow rate, gas pressure, current and voltage

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1. ATMOSPHERIC PRESSURE PLASMA BPS1000

VISUALIZATION

Process monitoring: wear, operating hours, settings, gas pressure and plasma ignition

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PLASMA

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 PLASMA

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2. LOW PRESSURE PLASMA

VISUALIZATION

Process control: gas flow rates, pressure control, action list, action symbolic

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2. LOW PRESSURE PLASMA

VISUALIZATION

Process monitoring: gas flow rates, pressure, plasma ignition

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PLASMA

PROCESS CONTROL

Gas flow monitoring Hour meter Power User level

management

Remote

maintenance

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PLASMA

STANDARD MACHINES

Table top

Manual/integration

plasma machine for

individual part

processing with

manual load and

unload

B5100-P/5200-P

Fully automated

plasma machines for

high production rates

and fully automated

part handling

Integration unit

Incl. cabinet, touch

panel and digital

handshake/profibus

B5600-P

Fully automated

plasma machine with

augmented traversing

range

B2000-P

Integration plasma

machine for small

batch production with

program change and

manual load and

unload

BPS-LP

Low pressure plasma

machine with full

process control and

integrated PLC

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PLASMA

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

THANK YOU

FOR YOUR ATTENTION