Trends in Surface Treatment for Multi-Layer · PDF fileTrends in Surface Treatment for...
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Trends in Surface Treatment for Multi-Layer Packaging
Presented by
Senthil Kumar
C.O.O.| Enercon Asia Pacific
Trends in Surface Treatment for Multi-Layer Packaging
Presented by
Senthil Kumar
C.O.O.| Enercon Asia Pacific
Major Presentation TopicsMajor Presentation Topics
Trends and Challenges – Multi-Film StructuresWet vs. Dry Trapping on Inks, Coatings & Adhesives Chemistry Effects on Interlayer AdhesionExperimental using Atmospheric Plasma Technology Results & Discussion Conclusions
Trends and Challenges – Multi-Film StructuresWet vs. Dry Trapping on Inks, Coatings & Adhesives Chemistry Effects on Interlayer AdhesionExperimental using Atmospheric Plasma Technology Results & Discussion Conclusions
Trends & Challenges –Multi-Film StructuresTrends & Challenges –Multi-Film Structures
Require structures which are:ClearGreat barrier performanceCan be used for retort to extend shelf life
Technology enabling:Bio-films w/ ethylene copolymer tie layers for sustainabilityMore layers, including micro- and nano-layersMust ensure no “misfit” with adhesive layers to avoid structural destabilization, decreasing interfacial adhesion
Require structures which are:ClearGreat barrier performanceCan be used for retort to extend shelf life
Technology enabling:Bio-films w/ ethylene copolymer tie layers for sustainabilityMore layers, including micro- and nano-layersMust ensure no “misfit” with adhesive layers to avoid structural destabilization, decreasing interfacial adhesion
Trends & Challenges –Multi-Film StructuresTrends & Challenges –Multi-Film Structures
As consumer marketplace expands globally, surface pretreatment requirements challenged:
New material combinationsMore 9-10 layer tear-resistant constructions requiredNano-multilayer films requiring increased printability, scuff resistance, high transparency , security. Flexible packaging converter trend toward higher-speeds, and away from inks which emit VOCs toward W/B and UV/EB curables.
As consumer marketplace expands globally, surface pretreatment requirements challenged:
New material combinationsMore 9-10 layer tear-resistant constructions requiredNano-multilayer films requiring increased printability, scuff resistance, high transparency , security. Flexible packaging converter trend toward higher-speeds, and away from inks which emit VOCs toward W/B and UV/EB curables.
PropositionsPropositions
Polymer film surface modification techniques improve acceptance of interfaces.
These techniques increase hydrophilic characteristics and surface –free energy.
Interlayer adhesion can be improved by applying high density, homogeneous surface modification techniques
Polymer film surface modification techniques improve acceptance of interfaces.
These techniques increase hydrophilic characteristics and surface –free energy.
Interlayer adhesion can be improved by applying high density, homogeneous surface modification techniques
PropositionsPropositions
Atmospheric plasma surface modification discharges are high density, non-filamentary, uniform, create hydrophilicity.
Study examines experimental data relating correlations between surface modification and interfacial adhesion effects.
Atmospheric plasma surface modification discharges are high density, non-filamentary, uniform, create hydrophilicity.
Study examines experimental data relating correlations between surface modification and interfacial adhesion effects.
Surface Modification PrerequisitesSurface Modification Prerequisites
Adhesion strength of inks, coatings, adhesives to polymers is relative to surfaces which are cleaned, micro-roughened, polarized and made hydrophilic.
Accomplished commercially by Web corona discharge (air plasma), flame plasma, variable chemistry plasma techniques
Adhesion strength of inks, coatings, adhesives to polymers is relative to surfaces which are cleaned, micro-roughened, polarized and made hydrophilic.
Accomplished commercially by Web corona discharge (air plasma), flame plasma, variable chemistry plasma techniques
Web Corona Surface Activation SystemsWeb Corona Surface Activation Systems
Web Flame Surface Activation SystemsWeb Flame Surface Activation Systems
Web Variable Chemistry Surface Activation SystemsWeb Variable Chemistry Surface Activation Systems
Measuring SuccessMeasuring Success
Peel AdhesionLap SheerTensile TestsFatigue/Tear Tests
Peel AdhesionLap SheerTensile TestsFatigue/Tear Tests
Wet vs. Dry Trapping on Inks, Coatings & Adhesives Wet vs. Dry Trapping on Inks, Coatings & Adhesives
Multiple interfacial layer adhesion sub-optimized.Rely on formulation chemistries for wet-to-wet, wet-to-dry adhesion, for in-line and off-line processes.Example 1: dry-trapping 2nd pass through printer, solvent-based interfaces can flake off due to wax content at surface layer.Example 2: “chalking” effect due to insufficient pigment binder for substrate adhesion.Example 3: binding-solvents and -oils drain through porous substrates, increasing delamination potential.
Multiple interfacial layer adhesion sub-optimized.Rely on formulation chemistries for wet-to-wet, wet-to-dry adhesion, for in-line and off-line processes.Example 1: dry-trapping 2nd pass through printer, solvent-based interfaces can flake off due to wax content at surface layer.Example 2: “chalking” effect due to insufficient pigment binder for substrate adhesion.Example 3: binding-solvents and -oils drain through porous substrates, increasing delamination potential.
Wet vs. Dry Trapping on Inks, Coatings & Adhesives Wet vs. Dry Trapping on Inks, Coatings & Adhesives
Water-based interfaces formulated w/non-water soluble binders composed of styrene-acrylic alkali-soluble binder and resin emulsion.
Water-based interfaces formulated w/non-water soluble binders composed of styrene-acrylic alkali-soluble binder and resin emulsion.
Wet vs. Dry Trapping on Inks, Coatings & Adhesives Wet vs. Dry Trapping on Inks, Coatings & Adhesives
As interfaces dry, ammonia and volatile amines leave and emulsion particles can “touch”, combine to form a surface film.
As interfaces dry, ammonia and volatile amines leave and emulsion particles can “touch”, combine to form a surface film.
Wet vs. Dry Trapping on Inks, Coatings & Adhesives Wet vs. Dry Trapping on Inks, Coatings & Adhesives
However, trapping these interfaces can trap volatile amines which can exist as salts, interfering with interface-to-substrate bonding.
However, trapping these interfaces can trap volatile amines which can exist as salts, interfering with interface-to-substrate bonding.
Experimental Experimental ObjectiveDetermine effectiveness of an appropriate surface pre-
treatment technology in promoting /optimizing dry trap interlayer adhesions.
ProtocolAtmospheric plasma pre-treatment of polypropylene substrate Establishment of base interface adhesion-to-substrate threshold. Re-treatment over base interface to determine appropriate wet-out/adhesion.
ObjectiveDetermine effectiveness of an appropriate surface pre-
treatment technology in promoting /optimizing dry trap interlayer adhesions.
ProtocolAtmospheric plasma pre-treatment of polypropylene substrate Establishment of base interface adhesion-to-substrate threshold. Re-treatment over base interface to determine appropriate wet-out/adhesion.
Process Variables Specification Additional Specifications
Substrate BOPP film 0.5 mil.
Pre-Treat Surface Tension 30 mN/m Dyne solutions/contact angle
Water-Based Ink INX Lamiall® Cyan none
Solvent-Based Ink INX Lamiall® White PU-based; Acetate, alcohol
Treatment System Enercon Plasma Argon + oxygen
Treatment Density 6W/ft2/min Base and interlayer
Ink Application Method Pamarco Hand Proofer 165 line engraved roller
Ink Drying Method Hot Air Dryer 1 min. ; 4 min. room temp.
Test Ink Adhesion Method ASTM F2252-03 3M Scotch 800 tape; 180⁰
Experimental Experimental
Experimental Experimental
Material: Polypropylene
Treatment: No post-treatment
Pre-Treat Tension: 37 mN/m
Result: 95% peel of ink
Material: Polypropylene
Treatment: No post-treatment
Pre-Treat Tension: 37 mN/m
Result: 95% peel of ink
Material: Polypropylene
Treatment: Atmospheric Plasma
Post-Treat Tension: 48 mN/m
Result: <1% peel of ink
Material: Polypropylene
Treatment: Atmospheric Plasma
Post-Treat Tension: 48 mN/m
Result: <1% peel of ink
Base & Interlayer Adhesion Tape Peel of Blue Water-Based Ink on White Background
Experimental Experimental
Material: PP + Solvent ink layer
Treatment: No post-treatment on solvent ink layer
Pre-Treat Tension: 30 mN/m
Result: Spotty interlayer adhesion
Material: PP + Solvent ink layer
Treatment: No post-treatment on solvent ink layer
Pre-Treat Tension: 30 mN/m
Result: Spotty interlayer adhesion
Material: BOPP + Solvent ink layer
Treatment: Atmospheric Plasma over first ink layer
Post-Treat Tension: 39 mN/m at ink
Result: >99% interlayer adhesion
Material: BOPP + Solvent ink layer
Treatment: Atmospheric Plasma over first ink layer
Post-Treat Tension: 39 mN/m at ink
Result: >99% interlayer adhesion
Base & Interlayer Adhesion Tape Peel of Blue Water-Based Ink on White Background
Experimental Experimental
Base & Interlayer Adhesion Tape Peel of White Solvent-Based Ink on Black Background
Material: Polypropylene
Treatment: No post-treatment
Pre-Treat Tension: 37 mN/m
Result: 100% peel of ink
Material: Polypropylene
Treatment: No post-treatment
Pre-Treat Tension: 37 mN/m
Result: 100% peel of ink
Material: Polypropylene
Treatment: Atmospheric Plasma
Post-Treat Tension: 48 mN/m
Result: <1% peel of ink
Material: Polypropylene
Treatment: Atmospheric Plasma
Post-Treat Tension: 48 mN/m
Result: <1% peel of ink
Experimental Experimental
Base & Interlayer Adhesion Tape Peel of White Solvent-Based Ink on Black Background
Material: PP + Solvent ink layer
Treatment: No post-treatment on solvent ink layer
Pre-Treat Tension: 31 mN/m
Result: Spotty interlayer adhesion
Material: PP + Solvent ink layer
Treatment: No post-treatment on solvent ink layer
Pre-Treat Tension: 31 mN/m
Result: Spotty interlayer adhesion
Material: BOPP + Solvent ink layer
Treatment: Atmospheric Plasma over first ink layer
Post-Treat Tension: 40 mN/m at ink
Result: >99% interlayer adhesion
Material: BOPP + Solvent ink layer
Treatment: Atmospheric Plasma over first ink layer
Post-Treat Tension: 40 mN/m at ink
Result: >99% interlayer adhesion
Results & Conclusions Results & Conclusions 1) Dry-trapping of solvent/solvent and water-base/water-
base inks with common formulations and without interlayer surface pre-treatment created poor adhesion.
2) Plasma pre-treatment of base layer to a minimum of 8 mN/m above base dry ink film layer surface tension = >99% interlayer adhesion on polypropylene.
3) Indication of inherent benefit in modifying base layer of dry-trapped inks.
4) Micro-etching of ink surface + removal of wax films5) Oxygen formed hydroxyl groups and molecular bonds6) Additional trials suggested to improve interlayer
adhesion between coatings, adhesives, paints, etc.
Thank You for your attention!Thank You for your attention!