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Surface Treatment - Page 3

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Abrasive techniques. Among conventional surface treatment techniques, mechanical abrasion serves only to increase the surface area of the material by "roughening" the exposed areas prior to coating or adhesive bonding. Mechanical abrasion can be achieved through dry blasting, wet blasting or hand/machine sanding. These processes can be very operator. sensitive, labor-intensive, dirty, and difficult to perform on the high-production volumes normally associated with packaging applications. To remove particulates or residues, a solvent wash usually follows mechanical abrasion. In many cases, the spent abrasive materials fall under the classification of hazardous substances and must be disposed of accordingly.


Liquid cleaning techniques. Liquid cleaning can be very useful for removing gross contamination. Fluid cleaning techniques for polymer surfaces fall into three main categories: hand wiping, solvent cleaning, and water-based washing. Hand wiping can be done with a variety of solvents, combination of solvents, or an aqueous solution of various chemicals. This process is very labor-intensive and is usually only employed in situations with low production volumes. Hand wiping can result in inconsistencies in quality due to either human error or the redeposition of soils onto the surfaces being cleaned from contaminated rags used in the process. Surface treatment by solvent cleaning is most beneficial in those cases where swelling of the polymer surface, due to solvent absorption, results in a rougher morphology that can improve the adhesion of coatings without adversely affecting the substrate's mechanical properties. The process uses inexpensive equipment and works reasonably well in many cases such as in the surface preparation of molded polymer parts for subsequent paint adhesive, or coating application. Solvent treatment processes can be conducted through wiping, immersion, spraying, or vapor degreasing. Typically, high-vapor-pressure organic solvents (alcohols, ketones, toluene, etc), chlorinated hydrocarbon solvents (eg, Freons, or 1,1,1-trichloroethane) or low-vapor-pressure organic solvents (terpenes, isoparaffins, lactates, esters, etc) are used in these processes (2). The major drawbacks of the technology are the environmental and process hazards associated with the use of large quantities of volatile chemicals, to the extent that any savings in equipment cost are usually offset by the increased cost of obligatory environmental controls. Also, solvent-based surface treatment has limited utility when a distinct change in the chemical nature of the substrate surface is desired. Water-based cleaning processes operate with relatively low costs, have low environmental impact, and are well suited for high production volumes. An industrial power washer usually consists of an overhead or floor conveyor with parts mounted on racks that pass through various spray stages. Most systems are composed of seven separate functions: precleaning, cleaning, rinsing, conditioner or rinse aid, deionized water rinsing, air blow off, and oven drying (3). However, for most commercial applications this technology requires capital investment for new equipment.


Chemical etching. Generally, chemical or acid etching is more effective in improving adhesion to polymers than liquid cleaning or solvent swelling. These processes cause specific chemical changes to the substrate surface, allowing greater chemical and physical interactions to adhesives or coatings. Some common examples of chemical etching processes for various polymer materials are listed in Table 2 (4). The chemical treatment of polyolefins in many cases incorporates the use of chromic-sulfuric acid mixtures (5). Previous studies have shown that for LDPE and HDPE severe roughening of the surface occurs. The effect of such treatments on polypropylene depends strongly on the prior thermal history of the polymer, and higher etch rates have been observed in areas of low crystallinity. There can also be changes in the polymer surface chemistry after chromic acid oxidation. Reflection ir spectra (6) show that this treatment results in the incorporation of oxygen (hydroxyl, carbonyl, and ester groups) and sulfur (SO3H)-containing functional groups in the LDPE surface. However, the precise chemical state of a polymer surface after chemical exposure is dependent on the nature and thermal history of the polymer, the composition of the etchant solution, and the time and temperature of the exposure. Often a process will work well for one material but will not be effective for another, necessitating specific treatments for each type of substrate. Also, chemical etching processes must be monitored closely as overexposure can result in overtreated, discolored, or damaged materials. In many instances, the etchant materials used can pose serious safety, hazard, and disposal problems. Although many of these processes can be effective in treating specific polymer materials, numerous users are seeking alternatives because of the concerns for operator safety and the complications of use and disposal.

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The Wiley Encyclopedia of Packaging Technology, Second Edition, Edited by Aaron L. Brody and Kenneth S. Marsh - ISBN 0-471-063975-5 © 1997 by John Wiley & Sons, Inc.

 

 



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