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. |