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Effiziente Veredlung von Vliesstoffen
mit Plasma- und Sprühsystemen
Hof, Nov. 2016
Alexander Rau
Efficient finishing of nonwovens
with plasma- and spray-systems
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Corona treater
Spray coaters
Hot air dryers
Products
2
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Web Process Line
3
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Corona Treatment of PP-Nonwoven
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What is a Plasma ?
Atoms
Energy
Gas Plasma
-
Atoms
+ Ions
electrons
Atoms electronically activated
Plasma is a gaseous mixture of ions, electrons, and atoms or molecules
5 5
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Corona = air-DBD
Working Principle
High Voltage Electrodes
Grounded Counter Electrode
„Corona-Light“ in the discharge gap
8 ceramic electrodes / roller with ceramic coating
6 6
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(CH2)n Polymer chain (Surface of PE)
Oxidation
Oxygen
Fragmentation
Air-DBD on PE Oxidation & Fragmentation
Polymer chain with oxygen groups 7 7
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Effect of air-DBD on Plastic Film
Number of oxygen atoms on the surface
Oxygen groups linked to the surface result:
Improvement of wetting and adhesion properties
Crosslinking of polymer chains result:
increase of melting point and weaker sealing properties
PP without corona No oxygen
PP corona treated max. 30 O-Atoms per 100 C-Atoms
Formation of OH groups 1 – 5 %
Formation of Oxygen Groups on the surface
Cross-Linking
5
10
nm
Types of oxygen groups
Hydroxy -OH
Acid -COOH
Keto -C=O
Aldehyd -CH=O
Peroxide -OOH
8 8
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Absorption of Water on PET Nonwoven
without Corona-Treatment
with Corona-Treatment
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Test inks on non woven
Polyolefin non woven 60 g/m²
without corona treatment
Test ink
34 mN/m Test ink
40 mN/m
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untreated Air-DBD treated
with ≈1000 W/min*m²
Air-DBD with high intensity on PP-Fibre
Increase of roughness due to fragmentation reactions
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The Unit of Treatment Corona and Plasma Dose
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Influence of corona dose on absorption of test inks
Corona-Dose [W*min/m2]
Test
Ink T
yp
e
[mN
/m]
30
34
38
42
46
50
54
0 200 400 600 800 1000
Spunbonded PP 33 g/m²
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Influence of corona dose on water absorption after dipping
Corona-Dose [W*min/m2]
Wate
r A
bso
rpti
on
[%
]
Spunbonded PP 33 g/m²
0
50
100
150
200
250
300
350
400
450
500
0 100 200 300 400 500 600 700 800 900 1000
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36
38
40
42
44
46
48
50
52
0 50 100 150 200
PP with few additives
Su
rfa
ce
Te
ns
ion
[m
N/m
]
Time [days]
Decay of surface tension with time
Decay depends on additives and polymer type
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Rotor Spray System Spray Application
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Video Rotor Spray System Spray Application
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Hydrophilic Finishing
of PP-Nonwoven
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Hydrophilic Finishing
of PP-Nonwoven
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Process steps
1) One sided air-DBD (on and off)
2) One sided spray of hydrophilic agent
0,15 - 3 % wt % ingredient
6 - 15 wt% wet
3) Hot air drying (> 10 % wet)
Material: Spunbonded PP 33 g/m²
1 2
3
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Influence of air-DBD on absorption of blue water
Spunbonded PP 33 g/m²
20
Without finishing 0,4 wt% hydrophilic agent
One sided air-DBD +
0,4 wt% hydrophilic agent
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Spunbonded PP 33 g/m²
Influence of corona treatment on absorption of water
21
Without finishing 0,4 wt% hydrophilic agent One sided air DBD +
0,4 wt% hydrophilic agent
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Less hydrophilic agent with corona treatment
Spunbonded PP 33 g/m²
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0,0
1,0
2,0
3,0
4,0
5,0
6,0
7,0
8,0
9,0
10,0
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5
Ab
so
rpti
on
tim
e [
s]
Add-on of hydrophilic agent [wt.-%]
with air DBD
without air DBD
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Hydrophobic Finishing
of Glass-Fibre Fleece
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Hydrophobic finishing
of GF-Fibre Material
24
Process steps
1) Two sided corona treatment (air DBD)
2) One sided application of sol solution with rotor spray (≥ 100 wt %)
3) One sided smoothing with driven roll (add on side)
4) Hot air drying
GF-Filter
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Hydrophobic finishing of GF Process Steps
Hot Air Drying
One sided
smoothing
One sided
spraying
Two sided
corona treatment (air DBD)
GF-Filter
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Influence of smoothing roll Spray of red colour on paper
Without smoothing
With smoothing
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PET non-woven 68 g/m2
One side spray application with blue agents
With air DBD
Without air DBD
Bifunctional finishing
Backside view
of add on
Spray Side
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Without air DBD
What can be sprayed
Glycols Ammoniumsalts
Sol/Gel-Systems Microcapsules 28
Examples
• Water based liquids with low viscosity
• Solutions, emulsions, dispersions (< 5 µ)
• Low and middle viscous oils
Antimicrobials Hydrophilic
Antimicrobials &
Hydrophobic
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Pilot Plant in Lauterbach /Hessen
28
Test your material
Come to
Lauterbach!
Thank you for listening
At your disposal
for any Questions