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Atmospheric Plasma Primer

Surface Treatment of Medical Surfaces

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Table of contents (bookmarks available to the left)

Page 2 Treatment Comparison Chart Page 17 Application:
Needle Hub Assembly bond strength
Page 3 White Paper:
Optimizing adhesion to polymers Page 18 Product Oveview:
Blown-ion, Blown-arc, Flame and
Page 8 White Paper: Variable chemistry plasma
Surface modification of polymers
for BioMedical Device Adhesion Page 19 Measuring Surface Energy

Page 14 Application: Page 20 Dyne Pen Order form

Pad Printing on Polypropylene
Page 21 Free Laboratory Trial Information
Page 15 Application:
Treatment solutions for wires/cables

www.enerconind.com/treating
Enercon Industries Corp. Menomonee Falls, WI USA Enercon Industries, Ltd. Aylesbury, Bucks UK
Tel: 262-255-6070 Fax: 262-255-7784 Tel: 44 1296 330542 Fax: 44 1296 432098
E-mail: info@enerconind.com E-mail: info@enerconind.co.uk
 Air
Plasma
By creating an electrical ionization
of air, air plasma emits ions and
free electrons to remove low
energy surface atoms. While
vaporizing inert contaminates
and residues, air plasma also
deposits reactive oxygen species
(ROS) to the surface.
Flame
Plasma
Flame ionization of hydrocarbon
gas forms reactive species,
increasing electron density and
distribution to the surface, while
polar functional groups and
oxidation enhance to the surface.
Variable
Chemistry
Plasma
The electrical ionization of various
gases create a uniform stream of
ionized gas. High density plasma
promotes surface cleaning, etching,
crosslinking, and deposition.
www.enerconind.com/treating
Enercon Industries Corp. - USA
262-255-6070 / info@enerconind.com
Advantages Considerations
 Low capital cost  Depth of treatment limited
 Easy operation
 Simple maintenance
 Low operation costs
 Suitable for lower line speeds
 Easy to install
 Ideal for most applications
Advantages Considerations
 Achieves high levels of treatment  May not be suitable for all heat
 Uniform treatment sensitive products
 High-velocity output  May not be suitable for low line speeds
 Treats well at high line speeds
 Long treatment life
 Flash off unwanted surface debris
 Treatment head available in any width
 Treats varying geometries and depths
Advantages Considerations
 Can vary chemistry by application  Operational costs dependent
 Low temperature treatment on application
 Ability to treat difficult materials  Depth of treatment limited
 Long treatment life
 Treats well at lower line speeds
 Ability to achieve high treatment levels
 Uniform treatment
Enercon Industries, Ltd. - UK
+44 1296 330542 / info@enerconind.co.uk
 SURFACE ACTIVATION SYSTEMS FOR OPTIMIZING
ADHESION TO POLYMERS
Rory A. Wolf
Enercon Industries Corporation
Abstract
Many experiments have been performed globally to
investigate ways of improving adhesion to polymers.
This paper discusses current atmospheric surface
activation systems, appropriate measurements of
wettability and adhesion, over-treatment effects and
surface analysis techniques relative to optimizing the
adhesion of inks, paints, coatings and adhesives to
polymer surfaces. Recommendations for improved
activation by substrate and application are discussed.
Atmospheric Surface Activation Systems
There are three primary types of atmospheric surface
activation systems for three-dimensional polymeric
surfaces – air plasma, flame plasma, and atmospheric
chemical plasma regimens.
An air plasma treating system is designed to increase the
surface tension of polymers in order to allow improved
wettability and adhesion of inks, coatings and adhesives.
As a result, the materials treated will demonstrate
improved printing and coating quality, and stronger
lamination strength.
The system consists of two major components:
1. The power supply
2. The treatment device
The power supply accepts standard utility electrical
power and converts it into single phase, higher frequency
power that is supplied to the treating device. The treating
device applies this power to the surface of the material,
through an air gap, via an electrode design. Only the side
of the material facing the high potential electrode should
show an increase in surface tension. When air is exposed
to different voltages, an electrical discharge develops.
When this occurs, neutral molecules and electrically
charged molecules collide. These collisions cause neutral
molecules to become electrically charged, resulting in
filamentary discharges or “streamers”. Such filamentary
discharges create a cloud of ionized air - or an “air
plasma”. When a plastic substance is placed under an air
plasma discharge, electrons bombard the treatment
surface with energies two to three times that necessary to
break the molecular bonds on the surface of most
substrates. The resulting free radicals react rapidly with
other free radicals on the same or different molecular
chain, resulting in cross-linking. Oxidative affects on
treated surfaces increases surface energy as a result of
polar groups being created on the surface, primarily in
the form of hydroxyl groups, carbonyl groups, amide
groups and carboxylic acid. Since exposures of treated
surfaces to high levels of ambient humidity and
temperature accelerates polymer side chain mobility and
treatment degradation, it is recommended that down-
stream plastic decoration take place directly following
treatment.
Air plasma systems are currently manufactured in two
forms, blown arc and blown ion. The blown arc form of
air plasma is easily distinguished by the bright flame-like
electrical arc that it forms. This sub-form uses two
electrodes though which air is blown between them
forming this arc-like shape. In this form, the substrate is
treated by coming into contact with approximately a
quarter of an inch of the arc. The blown ion form of air
plasma requires greater pressure of air past the electrode.
This sub-form utilizes a single electrode that discharges
inside the treater head. The great amount of pressure
allows the charged air to rocket out of the tip of the head
and form a deep, directed stream of charged ions.
Flame plasma is formed when a flammable gas and
atmospheric air are combined and combusted to form an
intense blue flame. The surface of materials are made
polar as species in the flame plasma affect the electron
distribution and density on the surface. Polar functional
groups such as ether, ester, carbonyl, carboxyl, and
hydroxyl are contained in a flame plasma; these are
incorporated into the surface and affect the electron
density of the polymer material. This polarization and
functionalization is made through reactive oxidation of a
surface. ESCA analysis shows that oxidation depth
through flame treatment is 5-10nm. This is generally less
in depth than air plasma treatment, where oxidation
depth is believed to be over 10nm. However, flame
plasma treatment’s extensive oxidation, due to reactions
with OH radicals in the flame, results in a highly
wettable surface which is relatively stable upon aging.
Flame plasma systems are manufactured with two
primary burner configurations – ribbon and drilled port.
Ribbon burners are typically constructed with a cast iron
body and with stainless steel ribbons which are meshed
(or opposed to each other) to construct varying pilot and
main flame patterns. As the open area of the ribbon
construction increases, so does the capacity of the ribbon
burner. Drilled port burners are typically manufactured
in brass, stainless steel or aluminum and offer the
flexibility of having varying port diameters and port
rows for wide design and treatment adaptations. The
substrate is optimally treated by flame plasma when it is
positioned approximately 5-8mm above the inner
luminous flame cones. Line speed and burner output will
affect this positioning.
Atmospheric chemical plasma treating systems generate
an electrically charged atmosphere similar to air plasma,
but uses chemical atmospheres in place of air to
introduce a wide range of surface modifications to a
substrate. The systems are characterized by their
generation of high density reactive species for low
temperature material processing. The chemical plasma
process can involve surface preparation via the
breakdown of low molecular weight organic materials
(LMWOM) and surface decontamination, fine etching of
the surface to create new topographies, grafting of new
functional groups or chemical species on the surface, and
the deposition of coatings on the surface. The treatment
process is designed to allow the interchange of gas
chemistries relative to the application requirements. In
the case of plastic parts, loose surface oligomers and
other residues are repetitively cleaved and degraded until
they are removed largely by a combination of
bombardment by ions and electrons. These organic
residues are converted into water vapor, carbon dioxide,
and other nontoxic gases or volatilized materials. A
noble carrier gas such as argon is typically used to
initiate the breakdown of LMWOM and create surface
etching for greater adhesion of paints, inks, coatings and
adhesives. The gas species which is ionized, along with
the composition and structure of the polymer itself, are
the key factors that determine the degree of etching. To
maximize adhesion of paints on plastics (particularly
thermoplastic olefins), the deposition of polar functional
groups from the use of oxygen and acetylene reactive
gases with the carrier gas can be particularly effective.
Atmospheric chemical plasma treatment systems are
typically non-thermal, atmospheric-pressure, glow-
discharge plasma systems which generate uniform and
homogenous treatments. The level of surface tension and
longevity of treatment are both typically greater than air
plasma treatment effects, and similar in treatment effect
to flame plasmas. The substrate is optimally treated by
atmospheric chemical plasma when it is positioned
several millimeters downstream from the source. Line
speed, power level, chemistry, chemistry mixtures and
material composition primarily determine levels of
etching and functionalization which can be achieved.
Measures of Wettability & Adhesion
Substrates such as plastics are generally composed of
non-polar, long-chain molecules. Polymeric surfaces
have a small amount of free energy. Fluorocarbons,
silicones and vinyls have particularly low free surface
energies. As such, plastics have few available bonding
sites due to low levels of charged ions on the surface. In
addition to low surface energies, plastics have diverse
levels of conductivity, may be composites in structure,
and may be blended with processing additives. All of
these variables can negatively impact molecular
attraction, causing liquids to fail to wet the surface. The
surface energy of plastics must significantly exceed the
surface tension of liquids by a recommended level of 10
dynes/cm to prevent paint or ink picking/liftoff and
delaminations.
Reliable and repeatable measures of wettability and
adhesion are critical to successfully painting, printing,
coating and laminating three-dimensional substrates. The
use of “dyne” solutions is the most common method of
measuring the surface tension of substrates. This process
uses varying proportions of formamide (HCONH2) and
ethyl cellosolve (CH3CH2OCH2CH2OH). The
percentage of each chemical used is dictated by ASTM
D2578-84, and directly correlates to surface tension of
the solution usually ranging from 30-70 dynes/cm. The
ASTM standard requires ambient temperature (23±2ºC)
and relative humidity (50±5%) test conditions, due to the
inverse temperature/surface tension relationships of
liquids. A sterile cotton swab is used to apply a thin
coating of the dyne solution to the substrate. If the dyne
solution does not bead up within two seconds, the
surface tension of the substrate is determined be at the
dyne level of the solution used or higher. This testing
method is fast and cost-effective. Use of a consistent
number of drops of dyne solution on individual swabs for
each test adds reliability to the method. Dyne markers
are also used in the industry, but care must be taken to
clean contamination from the tip following each test.
Contact angle is also often used to determine surface
tension, cleanliness, bondability, wettability, adhesion,
bio-compatibility and coating quality. Advancing angle
measurements best represent the wetting of the substrate
while receding angle measurements can predict the
adhesion characteristics of the substrate. In some cases,
the variation of the measured contact angle of the
pretreated surface from location to location is larger than
the average reduction in the contact angle by
pretreatment. To gather meaningful data, the same point
on the surface should be used to measure the contact
angles before and after pretreatment. This reveals the
change in contact angle due to cleaning while
minimizing the effect of surface variation.
Over-Treatment Affects
The primary objective of surface activation systems is to
introduce high energies to bombard ions against surfaces
and remove contaminants so a more stable polymer
surface is exposed. And in the case of a plasma discharge,
these bombardments can facilitate the further etching,
grafting or the deposition of surface coatings.
Excessive surface treatment can result in an extreme
bombardment of the base polymer which ultimately can
destroy the entire polymer part. Depending on the
treatment process, pin-holing, surface degradation (i.e.,
redevelopment of LMWOM), and accelerated treatment
decay rate are typical outcomes from atmospheric
surface activation system over-treatments.
Surface Analysis
Surface analysis and microscopy methods are key tools
in determining changes in surface topography and the
presence of deposited functional groups on substrates.
Appropriate techniques to maximize surface data for
plastics while minimizing cost and response time include
Atomic Force Microscopy (micrographs of atomic scale
roughness to resolution depths of .01nm), XPS/ESCA
(surface analysis of organic and inorganic molecules to
resolution depths of 1-10nm), and Time of Flight SIMS
(surface microanalysis of secondary ions, atoms, and
molecules to resolution depths of 1 monolayer).
Background & Development Effort
Because the processing of plastic substrates is typically
in-line or continuous from surface activation through the
adhesion of inks, paints, coatings and adhesives,
experimental focus was placed on determining the
treatment effectiveness of different atmospheric surface
activation systems on various plastic substrates rather
than on long-term treatment degradation profiles. As
such, an analysis was conducted of immediate post-
treatment surface energy as created by air plasma, flame
plasma, and atmospheric chemical plasma, and measured
by the use of dyne solutions and sterile cotton swabs.
Trials were conducted within the Enercon Industries
surface treatment laboratory at a processing speed of 50
fpm. Power outputs for Enercon-designed air plasma,
flame plasma and atmospheric chemical plasma systems
were controlled to standard design outputs. The flame
plasma treater utilized a triple slot burner, while the
chemical plasma system utilized helium and oxygen
chemistries. See Figure 1 for the results of this analysis.
Atmospheric Surface Activation Treatment Analysis
70
60
50
Dynes/cm
40 Air plasma
Flame Plasma
30 ACP
20
10
0
ABS Acrylic HDPE LDPE Nylon 12 PP PTFE PVC
Figure 1
Conclusions
ƒ With the exception of PTFE, the polymer substrates
chosen for this analysis were treated by air plasma,
flame plasma and atmospheric chemical plasma at or
above surface activation levels considered adequate
by industry standards for promoting the adhesion of
aqueous, solvent and UV-based (see Appendix).
ƒ High levels of reactive oxidation and surface
functionalization by flame plasma and atmospheric
chemical plasma, respectively, are assumed to be
key in generating dyne levels higher than air plasma
for all tested polymer substrates.
References
1. Markgraf, D.A., "Corona Treatment: An Overview,"
1986 Coextrusion Conference Proceedings, TAPPI
PRESS, Atlanta, p. 85.
2. Collins, W.M., "Classical Review of Corona
Treatment," 1983 Coextrusion Conference
Proceedings, TAPPI PRESS, Atlanta, p. 47.
3. Markgraf, D.A., "Ozone Decomposition in Corona
Treatment," 1985 Polymers, Laminations and
Coatings Conference Proceedings, TAPPI PRESS,
Atlanta, p. 227.
4. Pochan, M., et al, "XPS and Contact Angle
Investigation of Corona Treatment..," 1985
Polymers, Laminations and Coatings Conference
Proceedings, TAPPI PRESS, Atlanta, p. 109.
5. Markgraf, D.A., "Physical and Surface Chemistry of
Corona Discharge...," 1985 Polymers, Laminations
and Coatings Conference Proceedings, TAPPI
PRESS, Atlanta, p. 107.
6. Marra, J.V., "Surface Modification of Polypropylene
Film...," 1985 Polymers, Laminations and Coatings
Conference Proceedings, TAPPI PRESS, Atlanta, p.
103.
7. Schwab, F.C., et al, "Effect of Resin Additives on
Corona Treatment...," 1985 Polymers, Laminations
and Coatings Conference Proceedings, TAPPI
PRESS, Atlanta, p. 95.
8. Markgraf, D.A., "Practical Aspects of Determining
Level of Corona Treatment," 1985 Film Extrusion
Conference Proceedings, TAPPI PRESS, Atlanta, p.
65.
9. Whiteside, D.L., "Corona Treating of Substrates,"
1985 Polymers, Laminations and Coatings
Conference Proceedings, TAPPI PRESS, Atlanta, p.
89.
10. Markgraf, D.A., "Practical Aspects of Determining
Level of Corona Treatment," 1984 Polymers,
Laminations and Coatings Conference Proceedings,
TAPPI PRESS, Atlanta, p. 507.
11. Schuelke, G.W., "Modern Trends in Corona
Treating," 1984 Polymers, Laminations and
Coatings Conference Proceedings, TAPPI PRESS,
Atlanta, p. 249.
12. Markgraf, D.A., "Evolution of Corona Treating
Electrodes," 1983 Paper Synthetics Conference
Proceedings, TAPPI PRESS, Atlanta, p. 255.
13. Collins, W.M., "Recent Technological Advances in
Corona Treating," 1981 Paper Synthetics
Conference Proceedings, TAPPI PRESS, Atlanta, p.
129.
14. Cramm, R.H., et al., "Theory and Practice of Corona
Treatment for...," 1981 Paper Synthetics Conference
Proceedings, TAPPI PRESS, Atlanta, p. 1.
15. Zito, W.F., "Electrostatic Treatment of Films Watts
the Answer?" 1980 Paper Synthetics Conference
Proceedings, TAPPI PRESS, Atlanta, p. 181.
16. Spell, H.L., et al., "Surface Analysis of Corona
Treated PE...,". 1978 Conference Proceedings,
TAPPI
PRESS, Atlanta, p. 283.
17. Ristey, W.J., et al., "Degradation and Surface
Oxidation of PE..," 1978 Conference Proceedings,
TAPPI PRESS, Atlanta, p. 267.
18. Tietje, A., "Corona Treating Systems for Coater-
laminators," 1978 Conference Proceedings, TAPPI
PRESS, Atlanta, p. 173.
19. Maynard, P.W., "Electrostatic Treating to Promote
Adhesion to..,". 1976 Paper Synthetics Conference
Proceedings, TAPPI PRESS, Atlanta, p. 59.
20. Sherman, P.B., "Quartz, Ceramic or Rubber
Dielectric in Corona Treatment," 1985 Polymers,
Laminations and Coatings Conference Proceedings,
TAPPI PRESS, Atlanta, p. 341.
21. Sherman, P.B., "Corona Treat-mechanical not
Electrical Problem," 1985 Film Extrusion
Conference Proceedings, TAPPI PRESS, Atlanta, p.
45.
22. Markgraf, D.A., "Sizing: the Critical Element for
Effective Corona Treatment," 1989 Coextrusion
Conference Proceedings, TAPPI PRESS, Atlanta, p.
17.
23. Thompson, K., "Surface Treatments for Coex
Polymer Films/Coatings," 1989 Coextrusion
Conference Proceedings, TAPPI PRESS, Atlanta, p.
11.
24. Briggs, D., Brewis, D.M., and Konieczko, M.B.,
Journal of Material Science, 1 4, 1344-1348 (1979).
 Appendix
Industry Category Pre-Treated Components ABS ASA FP's PA PBT PC PE PET PMMA POM PP PPE PS PUR PVC TPU
Automotive Bumber Parts z z z z z
Electrical Components z z z z z z
Engine parts z
Fascia/cladding/side moldings z z z z z z z
Grilles/Opening Panels z z z z
Instrument Panel/Dashboard z z z z z
Interior Trim z z z z z z
Lighting z z z z
Quarter Panels z z z
Tubing z
Upholstery z z z z
Wheel Trim z z z

Medical Angioplasty Balloons z z

Catheters/Housings z
Filter Casings z z z
Microplates z
Needle Hubs z z z z z z
Optical Lenses z z
Petri Dishes z
Syringes z z
Tubes, Valves, Connectors z z z z z
Vials z

Electronic Cables z z
Circuit Boards z
Connectors z z z z
Fiber Optic Cable Jackets z z
Handheld Screens z
Housings z z z z z
Switches z
Wiring z z

Cosmetics/ Bottles z z z z z
Pharmaceuticals/ Caps z z z
Food Closures z z z
Jars z z z
Tubes z z z

Recommended Type (Corona, Flame, Plasma) C,F C, P P C,P P C C,F C C P F,P P C,P C,P C C,P
Surface Dynes (aqueous decoration/coating) 44-48 40-44 40-48 48-60 40-48 48-60 40-48 46-60 40-44 40-48 40-48 40-48 40-48 44-48 42-48 44-48
Treatment Dynes (solvent decoration/coating) 42-46 38-48 38-45 46-55 38-45 46-55 38-45 42-48 38-48 38-45 38-45 38-45 38-45 42-46 40-45 42-46
Type/Dynes Dynes (UV curables) 46-56 42-54 44-60 50-60 44-60 50-60 44-60 48-62 42-54 44-60 44-60 44-60 44-60 46-56 44-60 46-56
ATMOSPHERIC SURFACE MODIFICATION
OF POLYMERS FOR BIOMEDICAL
DEVICE ADHESION
Rory A. Wolf
Enercon Industries Corporation
Abstract Summary: Biomedical applications
require polymers that react properly with the
biological environment in which they are
employed. Since biocompatibility involves the
interface between the device and the biological
environment, surface modification techniques can
be critical to solve adhesion issues, avoiding costly
changes of materials. Atmospheric surface
modification techniques such as air plasma, flame
plasma and chemical plasma discharges can
positively affect medical polymers such as high
molecular weight polyethylene in a localized
manner to produce useful results, such as
increasing the hydrophilic nature of the surface or
crosslinking functional groups to the surface. An
in-depth examination of the design of these
atmospheric technologies relative to specific
biomedical materials and applications is presented.
Introduction: Plastics, polymers, and resins have
become widely accepted for in vivo and in vitro
medical applications. Many of these materials have
properties that lend themselves well to the
manufacture of medical appliances or devices; they
are relatively inexpensive and easily molded or
formed into complex shapes, and bulk physical
properties may be selected from a wide range of
parameters such as rigidity and temperature
stability. Unfortunately, fabrication procedures that
require bonding are difficult to achieve, and
biological interface reactions within the body or in
the laboratory can limit their in vivo and in vitro
performance.
Atmospheric pressure plasma technology offers a
new technique for easing these limitations by
modifying the surfaces of these polymers. By
altering just the first few atomic layers, the surfaces
of most medical polymers can be rendered wettable
so that adhesive bonding can be achieved to
troublesome materials such as polyolefins,
silicones, and fluoropolymers. In a similar fashion,
more exotic processes such as plasma grafting and
polymerization can produce totally new custom
surfaces without loss of the desirable
characteristics of the bulk material.
1
Vacuum, low pressure plasmas have traditionally
been used in the aerospace, semiconductor, and
electronics industries for more than 30 years for
cleaning, etching, and surface treatment of
various materials. Like vacuum plasmas,
atmospheric plasma treatments do not affect the
bulk of the materials and plasma treated parts are
generally visually and physically
indistinguishable from untreated parts.
Plasmas are now routinely used for controlling
the wettability of test tubes and lab vessels, for
pre-bonding preparation of angioplasty balloons
and catheters, for treating blood filtration
membranes, and to manipulate surface
conditions of in vitro structures to enhance or
prohibit culture cell growth.
Given enough energy, any gas can be excited
into a "plasma," which is a mixture of ions,
electronics, excited species, and free radicals.
There are many temperature and pressure
conditions where this phenomenon will occur.
But for practical considerations dielectric barrier
discharge plasmas are commonly generated at
radio frequency, enabling these processes to take
place at low temperatures (25-100ºC) and
atmospheric pressure where surface reactions
with polymers are feasible without bulk
interactions.
Plasma "treatment" usually refers to a plasma
reaction that either results in modification of the
molecular structure of the surface or atomic
substitution. Even with benign gases such as
oxygen or nitrogen, plasma treatment can create
highly reactive species at low temperatures. High
energy ultraviolet light is emitted in the process
which, along with the high energy ions and
electrons, provide the energy necessary to
fracture polymer bonds and initiate chemical
reactions at the surface. Only a few atomic layers
on the surface are involved in the process, so the
bulk properties of the polymer remain unaltered
by the chemistry while the low process
temperature eliminates concerns about thermal
modification or distortion of the bulk. Unique
reactions can be promoted by appropriate choice
of reactant gases, and unusual polymer
byproducts and structures can be formed.
In many instances, plasma cleaning with benign
gases such as oxygen or nitrogen provides
adequate surface activation for enhanced wetting
and adhesive bonding. With other targeted end
results or substrate materials, it may be necessary
Polyamide (nylon) 73° 15°
to utilize reactants which result in "grafting" or
surface chemistry modification to achieve the Polyimide 79° 10°
desired results.
Polycarbonate 75° 33°
Tefzel 92° 53°
It is frequently possible to select reactants that
form volatile byproducts upon reaction of the PFPE 96° 68°
plasma with the substrate material. These, upon
desorbtion from the surface of the treated material,
are removed by an exhaust system, resulting in Many intravascular devices, such as balloon
etching of the surface without the necessity for catheters, are assembled by adhesive bonding of
further scrubbing or neutralizing. polyethylene components. Chemical surface
activation or mechanical surface roughening
Biomedical Device Applications: Plasma techniques provide only modest bonding
treatment of polyethylene or polypropylene performance, with bond failures noted after as
disposable Petri or Assay dishes greatly enhances few as eight repetitive inflations. With plasma
wetting. Contact angles as low as 22º have been treatment, up to 40 repetitions are achievable.
demonstrated on these materials after brief oxygen Typical bond strength data are shown in Table 2.
plasma exposure (see Table 1). When these parts
are properly packaged after treatment, the contact Table 2.
angle has been seen to be stable for several years. Typical lap-shear bond
strengths (psi), without and
Conversely, many medical polymers can be made with plasma treatment.
extremely hydrophobic. Teflon-like films and other
similar surface treatments can be easily
accomplished on most polymers using fluorinated Without With
gases. For example, small diameter tubes can be Polypropylene 370 1380
treated so that when immersed in aqueous solutions
they do not draw fluid by capillary action. Polyethylene
370 1450
(low density)
One of the simplest techniques used to evaluate
Polyethylene
plasma surface treatment is a wetting angle test 315 3125
using a contact goniometer. Surface roughness and (high density)
substrate cleanliness need to be tightly controlled Nylon 850 4000
to obtain quantitative data. Standard wetting
solutions are often used to obtain accurate surface Polystyrene 570 4000
energy values.
Polycarbonate
410 928
(Lexan)
Most untreated polymers are only poorly wettable.
Initial contact angles may vary from 60-100º. Table Tefzel 410 3200
1 shows a sample of some typical contact angle
measurements:
An oxygen plasma not only removes organic
Table 1. residues but also chemically reacts with the
Typical wetting angles, surface to form strong covalent carbon-oxygen
before and after bonds, which are much more polar and more
Oxygen plasma treatment. reactive than the initial carbon-hydrogen bonds.
The increased polarity of the surface accounts for
the substantial increases in wettability and adds a
Before After degree of covalent bonding to the surface-
adhesive interface. (Note that other gases may be
Polypropylene 87° 22° used to attain similar results in instances where
oxidizing species may be harmful to components
Polyethylene 87° 22°
of the assembly.)

2
The bond strength ultimately realized will certainly
be affected by:
1. Initial cleanliness of the surface(s).
2. Wetting of the surface by the adhesive.
3. Cross-linking effects.
4. Chemical interaction of the adhesive with the
surface.
Any mold release compounds, unpolymerized
monomers, plasticizers, or additives that may have
migrated to the surface must be removed either by
plasma cleaning or washing before surface
modification is attempted. Immediate assembly is
usually advised after the surface has been prepared.
Once the surface has been optimized and bonded,
the bond is permanent and does not degrade over
time.
Biomedical Plastics & Adhesives. The strongest
advances in plastics usage involve engineered
resins such as polycarbonate and thermoplastic
elastomers, which have favorable cost-performance
benefits. Polypropylene, polyethylene,
polyurethane and polyvinyl chloride retain leading
positions in non-invasive medical products and
standard medical packaging due to their low cost
and amenability to radiation sterilization.
Polypropylene, like polyethylene, is a crystalline
thermoplastic which has excellent thermal and
chemical resistance properties and high moisture
resistance. Polypropylenes are specifically often
selected for their good mechanical properties, but
they are a difficult-to-bond substrate since they
feature no surface functional sites or inherent
surface roughness to which an adhesive can secure
itself. Polypropylenes are also characterized by
either linear or branched carbon chain polymers,
low surface energies, low porosity, and non-polar
surfaces. Polyethylene, and particularly low
density polyethylene, is a semi-crystalline
thermoplastic produced by way of a free-radical-
polymerization reaction. Although this polyolefin
typically has lower strength and hardness
properties, it offers numerous benefits including
flexibility, clarity, and enhanced impact and stress
cracking resistance. High-density polyethylene is
similar to low-density polypropylene in the
polymerization process used to obtain the resin.
However, the density of the polyethylene increases,
resulting in higher strengths, increased hardness,
and enhanced chemical and abrasion resistance.
3
Hard-to-bond plastics such as polyolefins are
most often assembled using adhesives. While
adhesives are the most versatile assembly
method for plastics, only a few industrial
adhesives offer suitable bond strengths on hard-
to-bond plastics. Cyanoacrylate, light-curing
cyanoacrylate, hot-melt and light-curing acrylic
adhesives have typically been used with typical
difficult-to-bond plastics. Acrylic adhesives are
also being introduced for use with hard-to-bond
plastics.
Cyanoacrylate adhesives are polar, linear
molecules that undergo an anionic
polymerization reaction. A weak base, such as
moisture, triggers the reaction causing the linear
chains to form. Many cyanoacrylate formulations
are available with varying viscosities, cure times,
strength properties and temperature resistance.
Cyanoacrylates form thermoplastic resins when
cured. Standard unfilled ethyl monomer based
cyanoacrylates typically exhibit low impact and
peel strengths, low to moderate solvent
resistance, and maximum operating temperatures
of 160-180 degrees F. They will fixture in as
little as three seconds. Rubber-modified
cyanoacrylate formulations offer improved peel
and impact strengths over standard
cyanoacrylates. The compounded rubber added
to ethyl formulations slightly increases fixture
time to 30 seconds to two minutes. Thermally
resistant ethyl cyanoacrylates can withstand
continuous exposure to test temperatures up to
250 degrees F. Light-curing acrylics cure by way
of a free radical reaction to form thermoset resins
when exposed to light of the appropriate
wavelength and intensity. Light-curing
cyanoacrylates are ethyl-based products that
have photoinitiators added to the formulation,
allowing them to fixture rapidly on exposure to
low-intensity light, and to cure in shadowed
areas. Physical performance characteristics of
these adhesives are similar to those of traditional
cyanoacrylates. Polyolefin hot melts provide
good resistance to moisture as well as excellent
resistance to polar solvents, acids, bases and
alcohols, offering superior adhesion to
polypropylene when compared to other types of
hot melts. Reactive urethane hot melts perform
well on hard-to-bond plastics, processing at
temperatures of approximately 250 degrees F
which is as much as 200 degrees F cooler than
EVA, polyamide, and polyolefin hot melts.
Descriptions of Equipment & Processes. Release
agents and other contaminations on molded and
formed medical parts, however, can impede the
performance of these adhesives dramatically if they
are not addressed with surface pretreatments such
as air plasma, flame plasma or atmospheric
chemical plasma.
An atmospheric air plasma treating system consists
of two major components, a power supply and
treatment station. The power supply accepts
standard utility electrical power and converts it into
single phase, higher frequency power that is
supplied to the treating device. The treating device
applies this power to the surface of medical plastics
through an air gap, via an electrode design. When
air is exposed to different voltages, an electrical
discharge develops. When this occurs, neutral
molecules and electrically charged molecules
collide. These collisions cause neutral molecules to
become electrically charged, resulting in
filamentary discharges or “streamers”. Such
filamentary discharges create a cloud of ionized air
- or an “air plasma”. When a medical plastic
surface is placed under an air plasma discharge,
electrons bombard the treatment surface with
energies two to three times that necessary to break
the molecular bonds on the surface of most
substrates. The resulting free radicals react rapidly
with other free radicals on the same or different
molecular chain, resulting in cross-linking.
Oxidative affects on treated surfaces increases
surface energy as a result of polar groups being
created on the surface, primarily in the form of
hydroxyl groups, carbonyl groups, amide groups
and carboxylic acid. Electron and ion
bombardment will also create a cleaning effect on
surfaces of medical plastics. Since exposures of
treated surfaces to high levels of ambient humidity
and temperature accelerates polymer side chain
mobility and treatment degradation, it is
recommended that down-stream plastic decoration
take place directly following treatment.
Atmospheric flame plasma systems are comprised
of a combustion/electrical station and a burner
assembly, manufactured with two primary burner
configurations – ribbon and enhanced velocity. A
flame plasma is formed when a flammable gas and
atmospheric air are combined and combusted to
form an intense blue flame. The surface of medical
plastics are made polar as species in the flame
plasma affect the electron distribution and density
on the surface. Polar functional groups such as
ether, ester, carbonyl, carboxyl, and hydroxyl are
contained in a flame plasma; these are incorporated
4
into the surface and affect the electron density of
the polymer material. This polarization and
functionalization is made through reactive
oxidation of a surface. ESCA analysis shows that
oxidation depth through flame treatment is 5-
10nm. This is generally less in depth than air
plasma treatment, where oxidation depth is
believed to be over 10nm. However, flame
plasma treatment’s extensive oxidation, due to
reactions with OH radicals in the flame, results
in a cleaned and highly wettable surface which is
relatively stable upon aging.
An atmospheric chemical plasma system is also
composed of a power supply and treatment
station whereby the system generates an
electrically charged atmosphere similar to air
plasma, but uses chemical atmospheres in place
of air to introduce a wide range of surface
modifications to a substrate. The systems are
characterized by their generation of high density
reactive species for low temperature material
processing. The chemical plasma process can
involve surface preparation via the breakdown of
low molecular weight organic materials
(LMWOM) and surface decontamination, fine
etching of the surface to create new
topographies, grafting of new functional groups
or chemical species on the surface, and the
deposition of coatings on the surface. The
treatment process is designed to allow the
interchange of gas chemistries relative to the
application requirements. In the case of medical
plastic parts, loose surface oligomers and other
residues are repetitively cleaved and degraded
until they are removed largely by a combination
of bombardment by ions and electrons. These
organic residues are converted into water vapor,
carbon dioxide, and other nontoxic gases or
volatilized materials. A noble carrier gas such as
argon is typically used to initiate the breakdown
of LMWOM and create surface etching for
greater adhesion of adhesives. The gas species
which is ionized, along with the composition and
structure of the polymer itself, are the key factors
that determine the degree of etching. To
maximize adhesion of adhesives on plastics
(particularly thermoplastic olefins), the
deposition of polar functional groups from the
use of oxygen and acetylene reactive gases with
the carrier gas can be particularly effective.
Atmospheric chemical plasma treatment systems
are typically non-thermal, atmospheric-pressure,
glow-discharge plasma systems which generate
uniform and homogenous treatments. The level
of surface tension and longevity of treatment are
both typically greater than air plasma treatment
effects, and similar in treatment effect to flame
plasmas. The medical plastic is optimally treated
by atmospheric chemical plasma when it is
positioned several millimeters downstream from
the source. Line speed, power level, chemistry,
chemistry mixtures and material composition
primarily determine levels of etching and
functionalization which can be achieved.
Application of Equipment and Processes. It was
theorized the application of atmospheric air plasma
and flame plasma surface pretreatment would
sufficiently clean the surface of polypropylene,
polyethylene and polyurethane - based medical
plastic parts of LMWOM following molding and
forming processes. If accomplished, this surface
improvement would be identified through surface
tension testing using ethyl cellosolve / formamide
(dyne) solutions, and subsequently through
adhesive adhesion testing. As such, an atmospheric
air plasma device (Figure 1) was employed with an
internal air blower to discharge a blown arc at
480W. The performance of this device was
compared with a flame plasma device (Figure 2)
with compressed air and methane inputs. The
stoichiometric ratio air/gas ratio was maintained at
10:1 to create a thermal discharge of 11,282
BTUs/hr.
Medical device manufacturers provided common
plastic part assemblies for conveyance beneath
each of the treatment devices at industry-standard
discharge gaps between treatment device head and
substrate to achieve optimum electron
bombardments.
Presentation of Data & Results. Trial
pretreatment conditions and results are shown in
Table 3. Results presented indicate a final dyne, or
surface tension, at which minimum adhesive
adhesion was achieved relative to assembly
requirements specified by the medical device
manufacturers supplying these materials.
Relative to conditions, it is noted that the airflow of
the atmospheric air plasma device optimized
treatment at approximately twice the airflow of the
flame treatment device, and the dwell time of air
plasma treatment was ten times that of flame
plasma. Although this is the case, the high velocity
and thermal output of the flame plasma device
created the necessity to distribute this output at a
higher (optimized) speed so as not to affect the
surface morphology of the trial materials. This
5
optimized speed met all medical device
manufacturer’s process requirements.
Interpretation of Data. It is evident from the
trial data that flame plasma effected a higher
level of cleaning and surface tension compared
to atmospheric air plasma through higher
electron bombardment, increased surface
electron density, and high surface oxidation.
The primary effect of the enhanced velocity
discharge burner relative to the flame plasma
device is interpreted to be related to 1) increased
treatment (bombardment) efficiency, 2) greater
power density transfer, and 3) a more
homogeneous discharge profile.
Results and Discussion:
Plastics usage in the healthcare field
encompasses several distinct markets, and
predominantly involving applications for
medical devices, biocompatible implant devices
and for medical packaging. Polypropylene,
polyethylene, polyurethane, polyethylene oxide,
styrene-acrylonitriles, polysulfones, liquid
crystal polymers, and polyvinyl chloride were
exposed to pre-treatment by plasma discharge
technologies to improve adhesion relative to
non-invasive biomedical products and standard
medical packaging due to their low cost and
amenability to radiation sterilization. Invasive
biocompatible / biodegradable plastics such as
aliphatic polyesters, PEG based polymers, PVA
and copolymers, natural polymers and
polyanhydrides have also shown surface
adhesion enhancement by plasma discharge
technologies.
Release agents and other contaminations on
molded and formed medical parts were found to
impede the performance of medical adhesives
dramatically if they were not addressed with
surface pretreatments such as air plasma, flame
plasma or atmospheric chemical plasma.
Results presented indicate a final dyne, or
surface tension, at which minimum adhesive
adhesion was achieved relative to assembly
requirements specified by the medical device
manufacturers supplying these materials. Flame
plasma effected a higher level of cleaning and
surface tension compared to air plasma through
higher electron bombardment, increased surface
electron density, and high surface oxidation.
Conclusion:
The use of low polarity polyolefins in the
manufacturing of medical device assemblies such
as catheters, syringes, tubings and other
components may be more suitably cleaned of
molding and forming organic contaminations and
functionalized using flame plasmas as opposed to Figure 1. Air Plasma discharge
atmospheric air plasmas for improved adhesive
adhesion.

References:
1. Salerni, C., Adhesives & Sealants
Industry, “Adhesive Technologies for the
Assembly of Hard-to-Bond Plastics”
(2003).
2. Jones, H.R.N. (Howard Richard Neil),
“The Application of Combustion
Principles to Domestic Gas Burner
Design”, E. & F.N. Spon Ltd.(1989).
3. Mittal, K.L., and Pizzi, A., “Adhesion
Promotion Techniques: Technological
Applications”, Marcel Dekker (1999).
4. Brewis, D.M. and Mathieson, I., Figure 2. Flame Plasma Discharge
“Adhesion and Bonding to Polyolefins”,
Rapra (2002).
5. J.R. Hollohan and A.T. Bell, Techniques
Air Plasma Flame Plasma
and Applications of Plasma Chemistry,
Material Initial Dyne Final Dyne Initial Dyne Final Dyne
John Wiley & Sons, New York, NY, 1974
6. Chapman, Glow Discharge Processes, PP 30 44 30 46
John Wiley & Sons, New York, NY, 1980 PE 31 44 31 46
7. T.J. Hook, J.A. Gardella, and L. Salvati, PU 31 40 31 42
Journal of Materials Research, 2, 132,
1987 Treat Width 50.8mm 150mm
8. D.S. Everhart and C.N. Reilly, Annals of Airflow 311lpm 150lpm
Chemistry, 53, 665, 1981
Treat Gap 6.35mm 41.3mm
9. M. Szycher and W.J. Robinson, Editors,
Ave. Speed 10fpm 100fpm
Synthetic Biomedical Polymers,
Technomic, Westport, CT, 1980
10. R. d'Agostino, Editor, Plasma Deposition,
Table 3. Trial Treatment Chart
Treatment, and Etching of Polymers,
Academic Press Inc., San Diego, CA,
1990
11. Jim Scheppele, “Surface Modification of
Plastics for Medical Device
Applications”;
http://www.a2c2.com/archive/699surface
mod.htm

6
 1st Quarter 2007

Booth 1544

Surface treatment improves print adhesion

for leading dental product manufacturer
As a leading producer of contract dental products Ranir LLC
keeps their customers smiling with a steadfast commitment to
quality. ISO 9001:2000 and ISO 13485:2003 certification is part
of the reason the company regularly earns awards such as “CVS
Store Brands 2006 Winner-Supply Chain Support.”
Their wide range of products includes floss, whitening prod-
ucts and toothbrushes. Recently Ranir Engineering Manager
David Featherston encountered a printing application that
required surface treatment.
In this case, toothbrushes purchased from China were to be
converted in the company’s Grand Rapids Michigan plant. The
polypropylene toothbrushes resist ink adhesion so Featherston
and is team set-out to specify an integrated printing and surface
1
treatment system.
Ranir selected Printex of Poway, CA for the pad printing
application. When Printex Vice President Robert Bowden identi-
fied the need for surface treatment he turned to Enercon.
“We enjoy working with Enercon because they are a single
source supplier of multiple atmospheric plasma treatment tech-
nologies. Because of this Enercon is able to match the best and
most cost-effective solution for each application,” says Bowden.
In this case an Enercon Dyne-A-Mite HP™ blown-arc air
plasma treater was specified. Blown-arc air plasma is formed by
blowing atmospheric air past two high voltage power electrodes
and is sometimes referred to as corona treatment. 2 3
The electrical discharge positively charges the ion particles
surrounding it. Through direct contact, these particles positively
charge the treated area of the object's surface. This makes the
surface more receptive to any applied substance such as inks.
Printex integrated Enercon’s surface treater into a single tur-
ret system. The base unit is Printex’s G2-60 pad printer. The tur-
ret also features an operator loading station, drying station, auto
e-ject station, protective light curtain and the ability to expand the
system with a second Printex printer for two-color printing. An
Allen Bradley PLC is used to control system operation which
prints 25-30 printed brushes per minute. 4
Featherston says Ranir has been impressed with the equip-
ment from both Printex and Enercon. The operation satisfies 1. An Allen-Bradley PLC controls the entire printing process
Ranir’s stringent production and quality control requirements and 2. Enercon’s Dyne-A-Mite HP™ prepares the surfaces for printing
positions the company for another year of sparkling smiles from 3. The Printex G2-60 pad printer prints 25-30 brushes per minute
4. An auto-eject system removes the toothbrushes from the station
their customers.

Improving adhesion for printing, coating, bonding, painting and labeling

 2nd Quarter 2008

Custom Wire Tech partners with K-Kolor

for mission critical printing on custom Medical Devices
Custom Wire Technologies of Port K-Kolor President Ron Kohl says,
Washington, Wisconsin offers contract "Enercon provided several rounds of
manufacturing of custom wire prod- complimentary lab testing to help us
ucts with capabilities for wire diameter
qualify the process." The trials proved
sizes as small as .001". Their productsthat the Dyne-A-Mite™ HP air plasma
are used in the medical field and require
surface treater makes the printing
mission critical performance. indelible. Kohl adds, "For medical
As an ISO 9001 certified operation printing applications it's imperative to
the company continually searches for follow the defined protocols.
ways to improve the quality of their Enercon's experience with medical Medical devices precisely rotate and traverse
products. In some cases this leads themdevice applications ensured the project under the treatment head for optimal results.
to take greater control of value went very smoothly."
adding operations. To automate the treatment process
The Custom Wire Technologies Boldig's team designed an integrated
facility features custom pieces robotic feeding system that precisely
of integrated manufacturingpositions and rotates the wire products
equipment specifically optimized for in the treatment zone. Printing is
the production of custom wire achieved with the pad printer which
products with excruciatingly tight utilizes a rotary fixture for rotational
tolerance specifications. printing. Since partnering with
K-Kolor, Custom Wire Technologies
In-house printing increased its printing throughput and The Dyne-A-Mite™ HP air plasma system
Until recently the company reduced the number of pieces rejected prepares medical devices for printing.

outsourced printing on their due to printing imperfections.

manufactured products. Seeing an the bottle and we still could not get the
opportunity to expedite manufacturing Other applications industrial grade velcro to hold the bot-
times by taking control of print The power of surface treating has tle in place." Boldig decided to pass the
operations President Bob Boldig made an impression on Boldig. "I'm bottle through the treatment zone of
developed a partnership with really impressed with the improvement the Dyne-A-Mite™ HP treater to see if
Wisconsin based K-Kolor. in adhesion these compact systems adhesion would improve. The results
K-Kolor provides expertise with provide. In fact, we tested the system were impressive.
ink jet and pad printing on a wide for a few other applications in "The bond created between the
variety of materials. When they found our facility." adhesive on the velcro backing and the
ink would not bond to a product made One of the other adhesion improv- bottle was so strong that it held up
from LLDPE they consulted with their ing applications involved an experi- while the bond between the velcro and
pad printing manufacturer which mental fixture the company was devel- the backing itself failed. As a manufac-
recommended a Marabu ink along with oping with a bottle and industrial grade turer a surface treater is a great tool to
an Enercon surface treater. velcro. "We used cleaning solvents on have in your facility," says Boldig.

Improving adhesion for printing, coating, bonding, painting and labeling

 e New Technology

New Plasma3™ VCP provides variable chemistry

atmospheric plasma for difficult to bond to surfaces
UNTREATED
Inks, coatings and adhesives
TREATED wet-out with surface treatment
When air plasma systems fail to
meet your adhesion requirements its
time to try Enercon’s new Plasma3™
VCP system. It’s ideal for difficult to
treat surfaces such as PTFE and
features Enercon’s patented plasma
delivery technology.
Powerful yet gentle in-line
atmospheric treatment is optimized to
clean, etch and functionalize a
wide range of materials that would
otherwise be unresponsive. This
eliminates expensive priming, batching
and hazardous chemical surface Effectively Treats
preparation processes.
Key to its success is the uniform and ABS, ASA, EPD, EVA, FP, HDPE,
dense plasma it generates which LDPE, PC, PE, PET, PMMA, PP, PS,
provides an aggressive and consistent PU, PVC, PBT, TPU, TPO, FEP, PTFE,
PFA, metals and much more.
treatment. What makes this system truly
unique is its versatility.
VCP is an acronym for Variable
Chemistry Plasma. The system may be
configured with unique chemistry
blends to optimize the effects of treat-
ment for different materials.
In addition to being effective treat-
ment results are also long lasting making
it compatible with operations that
require a build-up of inventory.
The system is specifically designed for
treating sheets, boards and objects with
minimal contour such as tubing and wire.
Schedule a free laboratory trial to see
the power of Plasma3™ VCP. Contact Plasma3™ VCP treats wires (above) and flat
us at info@enerconind.com. object such as sheets and boards (below).

e Tools of the Trade

Non-toxic
dyne pens
Booth 566 June Decorating and Assembly Conference Booth 2750
measure
surface energy

For more information on

Enercon’s unique formamide free
dyne pen formulation contact us
NEWS
Atmospheric Plasma Technology
2nd Quarter 2008

today. We’ll send you an www.enerconind.com/treating

informative pdf along with
ordering instructions. Enercon Industries Corporation
W140 N9572 Fountain Boulevard
P.O. Box 773
TO CONTACT US: Menomonee Falls, WI 53052-0773
Enercon Industries Corporation
Menomonee Falls, Wisconsin ADDRESS SERVICE REQUESTED
Tel: (262) 255-6070
info@enerconind.com
Enercon Industries Limited
Aylesbury, Bucks, United Kingdom
Tel: 44 1296 330542
info@enerconind.co.uk
Website:
www.enerconind.com/treating

© 2008 Enercon Industries Corp.

FOR IMMEDIATE RELEASE: 
Enercon Industries 
Contact: Mark Plantier, VP Marketing 
mplantier@enerconmail.com 262‐255‐6070 
 
Needle Hub Assembly Tensile Strength Increases  
with Atmospheric Plasma Surface Treatment 

MENOMONEE FALLS, WI- Enercon’s Dyne-A-Mite™ IT

atmospheric plasma treater is being used to promote
adhesion on needle hubs used in the medical industry. The
blown-ion discharge of the system treats the inside of
polypropylene hubs prior to bonding with needles.

Polypropylenes are specifically often selected for their good

mechanical properties, but they are a difficult-to-bond
substrate since they feature no surface functional sites or
inherent surface roughness to which an adhesive can secure
itself.

The Dyne-A-Mite™ IT bombards the polypropylene surface with a high speed discharge of ions
cleaning the surface of contaminants, micro-roughening the surface to create more bonding sites
and functionalizing for adhesion. Positive ion bombardment facilitates a micro-etching or
scrubbing (ablation) effect to remove (desorb) organic and inorganic contaminants from the
surface. The result is increased surface energy and wettability, providing needle manufacturers
with increased tensile strength.

The Dyne-A-Mite™ IT is available as a single treatment head system and the Dyne-A-Mite™
Elite offers up to four treatment heads controlled by a single touch screen interface. Each system
is capable of high speed production and can be easily integrated into new and existing lines.

Enercon Industries Corporation, headquartered in Menomonee Falls, WI, is a major

manufacturer of equipment for the plastics and packaging industries. The company supplies
custom built atmospheric plasma treating systems for rolls, webs, sheets, and three dimensional
objects.

### 

Enercon Industries Corporation W140 N9572 Fountain Blvd Menomonee Falls, WI 53051 USA 
www.enerconind.com   (262) 255‐6070  info@enerconind.com 
 Air Plasma Variable Chemistry Flame Plasma
Blown-Arc Air Plasma

Dyne-A-Mite™ VCP
Dyne-A-Mite™ Dyne-A-Flame™

Dyne-A-Mite™ HP
Dyne-A-Flame™
Blown-Ion Plasma3™ VCP Untreated

Plasma3™ VCP

Dyne-A-Mite™ IT
Dyne-A-Mite™ IT Elite
Enercon Industries Corp. - USA
262-255-6070 / info@enerconind.com
Determine which
technology is best
for your application.
Treated
Contact us to schedule
a free laboratory trial.
www.enerconind.com/treating
Enercon Industries, Ltd. - UK
+44 1296 330542 / info@enerconind.co.uk
Enercon Surface Treating Systems
TM

Formamide
Formamide
Water-Based EnerDyne Pens TM
Free!
free! Enercon’s new EnerDyne pens feature a water-based
formulation for human and environmental safety.

Testing surface energy has never been safer or easier.

Are you achieving the dyne levels you need? Do you know the dyne level of your
material prior to treating? Key to any surface treatment application is knowing your
starting and ending treatment levels. Enercon's EnerDyne™ pens provide a quick, safe
and simple means of testing surface energy.
EnerDyne™ pens are designed to indicate surface treatment levels on polymer based
substrates and establish that the material is correctly treated prior to applying inks, coatings,
paints or adhesives. Pens are available in 30/32/35/38/41/44/48/56/60/66
dyne levels.

EnerDyne™ pens provide easy to

read results on all types of surfaces

Water-Based Dyne Pen Test Procedure:

1. Remove the pen cap and briefly depress the tip on a clean surface until moist
Incorrect Dyne Level 2. Apply the solution over a test area of approximately 1 square inch.
3. Note the required time for the applied solution to break into droplets and/or
peripheral shrinkage to occur. Read the solution behavior by observing the center
Correct Dyne Level area of the applied solution. If the dyne solution does not break into droplets
and/or peripheral shrinkage after 4 seconds, repeat the test with the next higher
surface tension solution. If the solution breaks into droplets and/or peripheral
shrinkage in less than 4 seconds, repeat test with next lower surface tension solution.
4. Do not repeat test on the same area of material.
5. Repeat Steps 1 and 2 until the correct dyne level is determined. The correct dyne level will be equal to the solution
that holds for exactly 4 seconds before droplets or peripheral shrinkage occur.
6. As a general guideline surface coverage tension should be approximately 10 dynes higher than ink,
adhesive, or coating. This may not be the case for every application.
General Guidelines:
• Use of excessive solution will result in a false reading.
• Dyne Pens typically have a 6-12 month shelf life.
• Each pen is rated for the minimum dyne level that the ink will determine.
• Surface energy testing should be conducted immediately after treatment (air plasma, flame plasma, chemical plasma, RF gas).
• Treated surfaces are time sensitive and are affected by environmental conditions such as temperature and humidity.
• Do not touch or contaminate the surface to be tested. Dirty surfaces lose their wettability therefore clean test level area.
• Do not use contaminated or outdated pens.
• Store and use pens at room temperature.
• The inks should not be exposed to direct light. Therefore keep them closed when not in use. Also, repeated ink
exposure to air, will alter the dyne levels.Properly sealed pens prevent this from occurring
• Inconsistent or excessive pressure may provide a false dyne level reading

Note: EnerDyne™ pen testing provides a safe, fast and effective means of testing surface energy.
Surface energy in itself does not guarantee adhesion success.

P.O. Box 773 Menomonee Falls, WI 53052 USA Telephone: 262-255-6070 Fax: 262-255-7784
w w w.enerconind.com E-mail: info@enerconind.com
Enercon Surface Treating Systems
TM
EnerDyne Pen Set Order Form
Formamide
Formamide We appreciate your interest in our EnerDyne™ pen sets. Please complete this order
Free!
free!
form and fax it to us at 262-255-2462 for prompt order fulfillment. If you have any
questions please contact us at 262-255-6070 or info@enerconind.com.

Enercon’s new EnerDyne™ pens feature a water-based formulation for

human and environmental safety. Testing has never been safer or
easier than with EnerDyne™ pen sets.
Qty Part# Description Price
Quick Test Assortment
CM0112-SET-01 EnerDyne™ PEN SET $149/set
(30,32,35,38,41,44,48,56)
PICK 8
CM0112-SET-XX EnerDyne™ pens your choice $169/set
30/32/35/38/41/44/48/56/60/66
Select from our Quick
Test Assortment set or
Indicate dyne levels for custom set(s): Pick your own custom
set of 8 pens.

Purchase Order Number:

Shipping: (courier name/account number):

Ship To: Bill To:

Company Name:

Attn:

Address:

City, State, Zip:

Country:

TERMS: 100% cash in advance M & I Marshall and Ilsley Bank, Milwaukee, Wisconsin Routing and Transit Number
075000051 for the Account of Enercon Industries Corporation, Account Number 08-20-1889. SWIFT: MARLUS44

P.O. Box 773 Menomonee Falls, WI 53052 USA Telephone: 262-255-6070 Fax: 262-255-7784
www.enerconind.com E-mail: info@enerconind.com OS0388-03
Enercon 3D Surface Treating Customer Support
Free lab testing
Enercon offers you free laboratory testing
to determine which surface treatment
solution is best for your application. Test your application with air plasma, variable chemistry
Our team of application experts use air plasma and flame surface treatment technologies.
plasma, variable chemistry plasma and flame surface treatment technology to evaluate which technolo-
gy is most effective and economical solution for your application.
Enercon’s testing facilities also include capabilities for advanced surface measurements and analysis.
Dyne level, contact angle, and friction/peel testing are all part of our customer support package.

Procedure for sending your samples in for testing:

1. Call Enercon (262) 255-6070 for a Return Control Number (RCN)

Allow our experts to put your
application to the test.
2. Clearly mark the RCN# on the outside of your shipment to us
3. Ship to:
Enercon Industries Corporation
Attn: 3D Lab RCN# ________
W140 N9572 Fountain Blvd.
Menomonee Falls, WI 53051
4. To have samples returned to you after testing please provide your
preferred method of shipping, shipping account number and address.

Enercon world class support

Enercon is widely recognized for its leadership as a
customer focused supplier. Our commitment to you begins
with initial consultation and continues long after the instal-
lation of your system.

Enercon’s global network of sales and service representa-

tives work closely with your technical team before, during
and after installation and commissioning. They provide you
with technical advice and practical assistance to ensure your Enercon’s strategically located
operation runs at optimum efficiencies. representatives are ready to assist you.

Supporting our local representatives is a dedicated service team that includes mechanical, electrical and
application engineers ready to respond to your immediate worldwide service needs.

Enjoy "Hot Line" technical support 24/7/365.

Take advantage of free hands-on training courses at our factory with operational models at our test-
ing facility to simulate line conditions.

Depend on prompt field service and start-up assistance when you need it.

For more information visit our website www.enerconind.com or use the contact information below:

Enercon Industries Corporation

P.O. Box 773 Menomonee Falls, WI 53052 USA
Tel: 262-255-6070 Fax: 262-255-7784
www.enerconind.com e-mail: info@enerconind.com

OS0387