Extrusion bonding success improved with surface treating

Chances are you or someone you know has a secret family recipe for a great barbecue sauce, or chili or killer cheesecake. In each case there's probably a unique combination of ingredients that makes all the difference in the world.

As a professional in the extrusion industry you can probably relate the family recipe analogy to the "secrets" your company employs to make the ultimate laminating bond. Many companies have found the combination of ozone and corona to be a lethal combination when it comes to improving extrusion applications.

Improvements can come in two forms. In some cases the treatment combination is required to produce complex multi-layer structures with significant bond and heat seal strength. In other cases the right combination of treatment can have a huge impact on operating efficiencies.

Ultimately your substrate determines the best surface treating for your application. You might also be interested to know that there is scientific documentation to support the benefits of combining ozone and corona.

Enercon co-authored a technical paper that studied the statistical effects of ozone adhesion in the extrusion coating process.

The combination of ozone and corona significantly outperformed corona alone. Reduced air gaps, lower melting temperatures (which also reduces odor) and reduced coating weight translates into a faster, more efficient and more economical production line.

Figure 1
  Air Gap Melt Temp Coating Weight
Corona Treatment
24cm
315°C
15 g/m2
Corona and Ozone Treatment
19cm
295°C
13 g/m2
Note: Variables tested for 95% probability of successful adhesion of LDPE with Natural Kraft Paper

Add in the fact that heat seal strength is also improved by the combination of treatments, it's apparent that the proper use and operation of these systems is of paramount importance to your success.

Treatment locations

Where should you locate your ozonator and corona treaters for optimum performance? This picture shows a typical layout for a co-extrusion line with need for pre- and post-corona treatment.

Flame Treatment

Flame treatment can be effectively used to burn off fibers on paper products prior to laminating. Fibers can cause pinholing in the lamination which results in weaker bonding and unacceptable leaks.

4 treatment technologies, one source

Enercon is pleased to be able to offer you a single source for all your extrusion treatment needs. We can put together an attractive price on an ozonator, corona treater and flame treater for your next project. Call me at 262-255-6070 for more information.

We can also help you evaluate if atmospheric plasma technology will be your next secret weapon to boost your results even more.

By the way if you do have any "secret" family recipes that you want to share, send them to me.

Enercon's Vice President of Application Engineering, Tom Gilbertson, offers insight into mixing things up in the extrusion bonding process.