An apparatus and method are provided for surface treating the inside surfaces of hollow or three dimensional plastic objects. While the invention will be described with respect to plastic objects, it will be understood that other objects having a high dielectric strength, such as ceramics, cardboard, paper and wood, may be similarly treated. The surface treating is effected by selectively directing a high voltage plasma field to a selected interior surface of the object to enhance adhesion of various glues, inks and the like. The plasma field is generated in the interior of a tunnel directed into an opening of the hollow portion of the object to be treated. A specially designed electrode is supported from the opening to direct in a controlled manner the field to the selected interior area of the object to be treated. The electrode is supported from a high dielectric shield covering a central area of the opening to direct the plasma field around the shield to a laterally extending electrode below the shield. The electrode is supported from the shield by a conductive rod and is fashioned to extend in a spaced relation to the interior of the object to provide a proper energy level in the plasma to the area to be treated. A plurality of electrodes may be utilized to treat separate and selected interior areas of the object.

Apparatus and method for treating the interior surfaces of hollow plastic objects to improve their adherency to and compatibility with another component, such as polyurethane foam. The invention consists of creating a vacuum in the object and drawing a conductive gas inside the object. A pair of electrodes are spaced apart from each other, and a source of electricity is provided thereto of sufficient intensity to produce an electrical discharge across the gap between the electrodes when an object is in the gap between the electrodes. The electrodes are arranged with regard to the size and configuration of the object to provide ionization of the conductive gas inside the object to surface treat the inner walls.

A review is presented on the surface preparation of polymers and composites using atmospheric pressure plasmas. This is a promising technique for replacing traditional methods of surface preparation by abrasion. With sufficient exposure to the plasma afterglow, polymer and composite surfaces are fully activated such that when bonded and cured with epoxy adhesives, they undergo 100% cohesive failure in the adhesive. Depending on the material, the lap shear strength and crack delamination resistance (GIC) can be increased several fold over that achieved by either solvent wiping or abrasion. In some cases, a plasma-responsive layer must be incorporated into the top resin layer of the composite to achieve maximum bond strength to the adhesive. Adhesion does not correlate well with water contact angle or surface roughness. Instead it correlates with the fraction of the polymer surface sites that are oxidized and converted into active functional groups, as determined by x-ray photoelectron spectroscopy and infrared spectroscopy.

A low-temperature, atmospheric pressure helium and oxygen plasma has been used for the surface preparation of aluminum 2024 prior to adhesive bonding. The plasma converted the aluminum from a water contact angle (WCA) of 79° to down to 38° within 5 s of exposure, while sanding reduced the WCA to only 51°. Characterization of the aluminum surface by X-ray photoelectron spectroscopy revealed a decrease in carbon contamination from 70 to 36% and an increase in the oxygen content from 22 to 50% following plasma treatment. Similar trends were observed for sanded surfaces. Lap shear results demonstrated bond strengths of 30 ± 2 MPa for the sanded aluminum vs. 33 ± 1 MPa for plasma-treated aluminum, where sol gel and primer coatings were added to the surface preparation. Following seven days of aging, wedge crack extension tests revealed cohesive failure percentages of 86, 92, and 96% for sanded, plasma-treated, and sanded/plasma-treated aluminum, respectively. These results indicate that atmospheric pressure plasmas are an attractive alternative to acid treatment or abrasion techniques for surface preparation prior to bonding.

Enhancement of the surface wettability and surface free energy of thermoplastic materials is an effective way of improving their adhesion and consequently the adhesive joint strength. A nanosecond pulsed Nd:YAG laser was selected in this work to provide energetic treatment of PEEK surfaces, in order to investigate its effectiveness in increasing the performance of lap shear adhesive joints. The laser was used to irradiate the PEEK, by rastering a spot of ca. 1 mm diameter across a large area. The resulting surfaces were characterised using single lap shear testing, confocal laser scanning microscopy, contact angle analysis, FT-IR, XPS and ToF-SIMS. Single lap shear testing of PEEK joints showed that the strength of adhesively bonded joints is greatly improved by laser treatment, up to 13 times that of untreated PEEK. Confocal laser scanning microscopy showed that the higher laser power intensities (≥107 W mm−2) disrupted the surface of the PEEK more than the lower laser power intensities (<107 W mm−2), but also showed that, as expected, only some of the surface is treated by the laser. Contact angle analysis showed a decrease in water contact angle with increasing laser power intensity, and the derived surface free energy increased accordingly. FT-IR in the specular reflectance mode showed no discernible change but XPS and ToF-SIMS did, suggesting that laser treatment only affects the near surface at the extremity of the 1–2 μm sampling depth. XPS showed a decrease in the carbon/oxygen ratio of PEEK on treatment, indicating that oxygen-containing functional groups were being created at the surface. XPS also suggested a cleaning mechanism at a laser intensity of 7.83×106 W mm−2, progressing to surface modification from a laser intensity of 107 W mm−2 and above. ToF-SIMS confirmed that laser treatment cleans the surface of PEEK of extraneous material.

The present invention relates to the treatment of plastic coated paper, and more particularly to the treatment of plastic coated paper to improve the adherence of ink and adhesives thereto. The principal utility of the invention at the present time resides in the treatment of polyethylene coated paper, and, for convenience, the invention will be described primarily in connection with tre-atment of such polyethylene coated paper. But it should be understood that the principles of the invention are applicable to the treatment of other plastics which may be coated on paper and which plastics exhibit generally similar response to the treatment of the invention, particularly polymers and copolymers of the lower olens. Similarly, the principles of the invention are also applicable to the treatment of certain plastic coated substrates other than paper.

The first part of the contribution deals with the interfacial tension, σ, of phase‐separated polymer solutions in single or mixed solvents and of binary polymer blends as a function of the relative distance to the critical temperature of the system, special attention being paid to the possibilities of theoretical prediction. Two methods are discussed in more detail. One is based on a realistic description of the Gibbs energy of mixing as a function of composition, the second correlates σ with the length of the measured tie line. The second part is devoted to another aspect, namely the effects of additives on the interfacial tension between the coexisting phases of demixed polymer solutions and between highly incompatible polymers. In the former case, it is demonstrated that an addition of a thermodynamically good solvent is normally associated with a reduction in σ; however, adding a high‐molecular‐weight compound which is incompatible with the dissolved polymer leads to an increase in σ. The interfacial tension between incompatible homopolymers is efficiently reduced by block copolymers consisting of monomeric units which are either identical with or different from those of the homopolymers; in contrast to theoretical expectation, the molecular architecture of the additives seems to be of minor importance only. Random copolymers which are insoluble in the homopolymers can also efficiently reduce the interfacial tension.

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.

The use of gas and/or liquid-phase carbon dioxide (CO2) with atmospheric plasma discharge surface pretreatment technology can remove micron and submicron particulates and hydrocarbon-based contaminations on plastics and metals. The cleaning process is based upon the expansion of either liquid or gaseous carbon dioxide through an orifice. The paper provides an understanding of the basic removal mechanism and provides experimental evidence of remarkable adhesion improvements relative to a broad range of applications in electrical, medical, and automotive manufacturing communities.