Frequently Asked Questions

Here you find frequently asked questions about our plasma products.

Further questions?

Table of contents

PiezoBrush PZ3
PiezoBrush PZ3-i
PlasmaBrush PB3
PlasmaBrush PB3 Integration
PlasmaTool
MediPlas

PiezoBrush PZ3

Is the PiezoBrush PZ3 a corona device?

No, the PiezoBrush is a jet with the advantages of more intensive treatment and less charge transfer.

Which materials can be processed?

In principle, all materials can be processed. With metals, care must be taken to avoid electric flashovers. With regard to working speed and effect, please refer to the application reports.

Is it possible to feed in external gases?

Yes, the Multigas Module allows the use of other process gases such as nitrogen and the noble gases helium and argon.

What is the optimum working distance?

For the Nearfield and Nearfield Needle Modules, the optimum working distance is 0.5 - 2 mm, for the Needle Module 2 - 5 mm, for the Standard Module 2 - 10 mm and for the Multigas Module 2 - 20 mm.

How fast must the PiezoBrush be moved over the surface?

Depending on the application, a treatment speed of up to 20 mm/s is recommended.

How much does the adhesion of my bonded area increase?

Adhesion strongly depends on the material and adhesive. Please read the application reports.

How long does the activation effect last?

The decrease in time of plasma activation (hydrophobic recovery) varies greatly. It is based on three main influencing factors: the plasma treatment (e.g. selection of process gas and plasma solution), the nature of the treated substrate and the storage conditions (e.g. temperature, relative humidity). Accordingly, further processing should take place as soon as possible after plasma treatment.

How can I make the activation effect visible?

In the simplest case, you will achieve good water wettability (72mN/m), which you can check with a simple water ink.

Can I process a component for too long?

Due to the low temperature of the generated plasma, an overtreatment as it often occurs with conventional plasma systems due to thermal stress is not possible with most modules. Only with the needle module is there a higher concentrated temperature input.

Can the PiezoBrush clean components?

Thin layers of release agent or adsorbates can be removed (fine cleaning). Thicker layers are not removed.

What modules are available for the PiezoBrush?

There are currently five different exchangeable modules: the Standard, Nearfield, Needle, Nearfield Needle and Multigas Module. These are also suitable for the piezobrush PZ3-i.

How often must the module insert be changed?

In normal operation, the module insert hardly wears out. However, depending on the working conditions, discoloration may occur after a few hundred hours of operation.

Is there a holder for the hand-held unit for even treatment?

Yes, a stand is available as an accessory for the PiezoBrush PZ3. The device can be clamped in this to ensure uniform treatment of substrates.

Does the PiezoBrush emit UV light?

The light emission of the PiezoBrush during air operation is very low and completely harmless.

How high is the ozone emission?

In air operation, the PiezoBrush generates ozone with a maximum concentration of 10ppm and a quantity of 25l/min. For continuous operation, an exhaust system with activated carbon filter is recommended.

Can the PiezoBrush damage the skin?

If the PiezoBrush is brought so close to the skin that an electric arc ignites, a local superficial burn may occur.

Can the PiezoBrush cause a dangerous electric shock?

No, the amount of charge and the current strength that can be directly transmitted is too small.

PiezoBrush PZ3-i

What treatment widths are typically achieved?

The treatment width depends on the process gas used. When using compressed air, an average treatment width of 2 - 29 mm is achieved, depending on the module. With nitrogen, treatment widths of up to 50 mm are possible. Larger treatment widths are also possible by arranging several units.

At what speed does the plasma treatment take place?

The treatment speed depends on the application, the substrate and other process parameters. For fine cleaning, a speed of approximately 1 - 50 mm/s is achieved, for bonding 10 - 150 mm/s and for printing processes 100 - 1,500 mm/s.

How high should the extraction rate be (in m³/h)?

The recommended gas flow through the unit is 8 - 20 sl/min. The extraction rate should be approximately ten times the total gas flow. Thus, the extraction rate should be at least 6 m³/h.

Can error sources (temperature / plasma) during plasma treatment also be determined via the I/O interface or only via the LED display?

The LEDs directly access the internal electronics of the unit. With this solution, a separate pin is required for each signal. However, with the digital BUS communication it is also possible to read out the error messages in detail directly via the communication line.

How long can the plasma treated parts be stored before further processing?

The time taken for plasma activation to decrease (hydrophobic recovery) varies greatly. It is based on three main influencing factors: the plasma treatment (e.g. selection of process gas and plasma solution), the nature of the treated substrate and the storage conditions (e.g. temperature, relative humidity). Further processing should therefore take place as soon as possible after plasma treatment.

Can electronic components also be treated with it without hesitation?

The treatment of electronic components with PiezoBrush technology must be tested in advance. High electric fields occur during plasma generation, which can damage electronic components.

Can all devices be controlled together in a line-up solution or must each device be controlled individually?

Both are possible. The control depends on the individual integration solution. In the case of the simpler communication by means of switching signals, each device must be provided with its own communication line and controlled with its own switching signals. When using digital bus communication via the CANopen protocol, the devices can be provided with short communication lines (“daisy-chain”) and only one “long” communication line is required. The control of individual devices, groups or all devices simultaneously can then be solved in many ways by the customer via programming.

What is the purpose of changing the rotation angle of the module carrier?

In the case of the Standard and Nearfield Modules, the plasma discharge is strongest at the corners, which can negatively affect the homogeneity of the plasma treatment. By rotating the module, a more uniform treatment of the substrate is achieved. For optimum homogeneity at maximum treatment width, please select an angle of 45°. For optimum homogeneity at maximum treatment intensity, please select an angle of 14°/76° (depending on the direction of travel).

What is the temperature of the generated plasma?

A cold-active plasma with a temperature of less than 50°C is generated.

Can the device be used on all materials?

Basically, all materials can be treated with the PiezoBrush PZ3-i. However, the correct module must be selected depending on the material; the conductivity of the material or assembly is decisive here. For non-conductive materials such as most plastics, the Standard or Needle Module is used. For conductive materials such as metal, on the other hand, the Nearfield or Nearfield Needle Module is used. If conductive materials are covered by non-conductive ones, treatment with the Nearfield or Nearfield Needle Module should also be considered.

Is it possible to overtreat the surface?

Is continuous operation of the unit possible?

Yes, the unit has been specially designed for 24/7 use. For manual use we recommend the piezobrush® PZ3.

How safe is it to work with the PiezoBrush PZ3-i?

The highly efficient plasma discharge requires very little power and is therefore harmless even when in contact with skin. A risk due to resulting gas emissions can be excluded by operating the device with an appropriate extraction unit. Ozone quantities of more than 0.2 mg/m³ can be generated.

PlasmaBrush PB3

Which materials can be processed?

All Materials can be processed. Basically, all materials can be treated with the plasmabrush® PB3. Conductive materials can be treated particularly effectively due to the transfer of the arc.

What is the temperature of the generated plasma?

The temperature distribution within the plasma flame is between 200 degrees and goes up to 1000 degrees, this differs greatly according to the particular nozzle types.

What is the optimum working distance?

For surface treatment, the optimum distance is typically between 6-25 mm.

How fast should I move the PlasmaBrush PB3 over the surface?

The optimum processing speed is very material-dependent, and can be calculated as a first approximation. Consult our application engineers.

What are the operating modes for the PlasmaBrush PB3?

For ordinary surface activation or fine cleaning to increase the wettability of a surface, the diffuse mode of operation is suitable, in which the plasma interacts with the substrate surface without any further measures. If one wants to remove an organic layer on the substrate, a so-called cathodic cleaning by means of a transferred arc is suitable. By grounding the substrate, the nozzle no longer acts as the cathode, but the substrate itself. Due to the greatly increased intensity of the treatment, thin layers of paint, for example, can be removed.

How long does the surface activation last?

The surface energy will decrease after the treatment on a timeframe of minutes to days. However the surface energy will allways remain higher than the initial value.

How can I make the activation effect visible?

In the simplest case, you will achieve good water wettability (72mN/m), which you can test with a simple water ink. Of course, there are also special test inks for a more precise analysis.

Can I overtreat a component?

Yes, you can cause thermal damage or the surface energy will decrease if the component is overtreated.

Can the PlasmaBrush clean components?

Yes, the PlasmaBrush is ideally suited for cleaning components. With suitable selection of the process parameters, oils, emulsions and release agents are removed.

Is a gas supply necessary?

Yes, operation is possible with industrial compressed air or nitrogen via a standardized Festo hose connection. The operator only has to ensure the appropriate gas flow in the range between 30-70 slm. A Festo MFM (Mass Flow Meter) can be used for this purpose, for example.

What power supply does the device require?

The PlasmaBrush can be operated via a standard household power socket.

How often should the nozzle and the electrode be exchanged?

In normal operation with air, a nozzle change is recommended every 500h. The electrode lasts approx. 1,000h.

Is the offered system ESD proof?

Yes, the A250 nozzle of our PlasmaBrush PB3 system is specifically designed for the treatment of ESD sensitive parts.

Can multiple plasma heads be used on one generator or does each head require a separate control unit?

Each PlasmaBrush PB3 system consists of the high voltage source PS2000 (compact design for integration in 19" racks), 9 m of high voltage cable (suitable for robots and drag chains) and the plasma generator PG31 (very compact, weighing less than 1 kg).

How many different recipes/parameter settings are possible?

The PlasmaBrush PB3 allows for power as well as frequency setting at the high voltage source. Other important parameter include the choice of nozzle, the choice of process gas (CDA, nitrogen, forming gas, etc.) and the gas flow (35-80 slm).

If several recipes/parameter settings can be used: What is the concept to import, load and use different internally stored recipes?

Since the most important process parameters are speed and nozzle-susbtrate distance we determine these in close coordination with the process owner. If changes have to be made to the parameters of the high voltage source these can simply be accessed via the communication interface.

Can recipes/parameter settings be imported via MES or the SPS of the production cell?

Yes, the PlasmaBrush PB3 system can communicate via CANopen (Standard), EtherCat, Profinet, Profibus, etc.

Are different nozzles / different nozzle designs available?

Three different standard noozle designs are available: A250 for ESD sensitive substrates, A350 for temperature sensitive materials and A450 for high-speed processes. We also offer long-life versions of our standard nozzles.

What's the concept on how to exchange the nozzles?

Nozzles can be exchanged without tools by instructed personnel.

What's the range of the possible treatment area / width?

The treatment width of the PlasmaBrush PB3 system ranges between 15 and 25 mm for one pass. Larger widths can either be achieved by the use of additional plasmagenerators or by meandering which is easily possbile due to high process speed and lightweight plasma head.

What's the available power range?

The plasma jet output ranges from 480 - 770 W.

Which process parameters are controlled / monitored / tracked?

The PlasmaBrush PB3 system allows the control of power and frequency. Via the communication interface of the high voltage source PS2000 power, current and voltage of the plasma jet can be monitored in real time.

How is the PlasmaBrush PB3 controlled?

The standard communication is via CANopen. However, control via USB interface is also possible. We would be pleased to support you with the integration into your plant, e.g. with the control via Profi-Net, Profi-BUS, EtherCAT.

Which data can be sent through this interface? Which data formats are available?

The CANopen project directory is listed in the manual (see page 16-20) and includes object types (VAR, ARRAY, RECORD, etc.) and data types (VISIBLE_STRING, UNSIGNED8, etc.). The .eds-file is included in the scope of delivery.

Which process exhaust gases occur during the plasma process?

The PlasmaBrush PB3 system generates exhaust gases typical for high power jet plasma systems, like NOx and ozone. The quantities are dependent on the process gas. Detailed analysis are available.

Was the electromagnetical radiation measured for your system?

The PlasmaBrush PB3 system is CE certified and complies with all relevant regulations. Both certification and analysis are available.

How can the PlasmaBrush be mounted?

The compact and lightweight (approx. 0.5kg) plasma generator can be integrated into an existing system by means of a simple bracket. We will gladly send you the drawing files for this purpose.

What's the typical size, weight etc. of the plasma system?

The PlasmaBrush PB3 is a modular system consisting of: high voltage source PS2000 for 19 inch rack (448x343x177,18 kg), high voltage cable suitable for robot and drag chain (9 m) and plasmagenerator PG31 (1 m cable length, 32 mm diameter, 680 g). Please find all relevant data in the manuals attached.

How safe is it to work with the PlasmaBrush?

Do not reach into the plasma flame during operation. The system can easily be integrated into the emergency stop circuit. The resulting emissions must be extracted, for this we recommend a volume flow of about 30m³ per hour.

Does the PlasmaBrush PB3 emit UV light?

Yes, but the UV emission using air is of low intensity and harmless at normal working distances of >200mm.

Does the PlasmaBrush PB3 emit dangerous gases?

Depending on process conditions the PB3 can emit ozone or nitroxides. We recommend to use an active filter or to exhaust the gas load into a hood.

Can the PlasmaBrush PB3 cause dangerous electric shock?

No, the amount of charge and the current are too low to be dangerous.

PlasmaBrush PB3 Integration

How is the PlasmaBrush PB3 integration controlled?

For easy handling, operation is possible with optionally available remote control. Alternatively, operation also works via a higher-level system control.

Which materials can be processed?

Basically, all materials can be treated with the PlasmaBrush PB3 Integration. Conductive materials can be treated particularly effectively due to the transfer of the arc.

What is the temperature of the generated plasma?

to 1000 degrees. It differs greatly depending on the nozzle used.

What are the operating modes for the PlasmaBrush PB3 Integration?

Is it possible to overtreat the surface?

Eine Überbehandlung der Oberfläche ist möglich, allerdings können thermische Beschädigungen der Oberfläche durch Abstand und Relativgeschwindigkeit ausgeglichen werden.

Can the device be used on all materials?

Basically, all materials can be treated with the PlasmaBrush PB3 Integration. Conductive materials can be treated particularly effectively due to the transfer of the arc.

PlasmaTool

What is the temperature of the generated plasma?

The temperature distribution within the plasma flame is between 200 degrees and goes up to 1000 degrees. It differs greatly depending on the nozzle used.

Is an over-treatment of the surface possible?

An over-treatment of the surface is possible, but thermic damage to the surface can be compensated by distance and relative velocity.

What are the operating modes for the PlasmaTool?

Is a gas supply necessary?

No, the compressed air for the plasma process is generated internally in the device by an integrated air compressor.

How heavy and how big is the PlasmaTool?

The PlasmaTool weighs approx. 60 kg and has a size of 800 mm x 540 mm x 430 mm.

Can the PlasmaTool be used on all materials?

In principle, all materials can be treated with the PlasmaTool. With conductive materials, a particularly effective treatment can be carried out by transferring the arc.

What power supply does the PlasmaTool require?

The PlasmaTool can be operated via a standard household SchuKo socket.

How safe is working with the PlasmaTool?

The handling of the PlasmaTool is designed for simple operation and the safety of the user. The two-hand operation and the warning light protect the user and third parties. A risk due to gas emissions can be excluded by operating the PlasmaTool with an appropriate extraction unit or good ventilation of the working area.

MediPlas

What is the MediPlas system?

The MediPlas system consists of the reactor and the driver. The MediPlas Reactor generates reactive oxygen and nitrogen species (RONS). The MediPlas Driver serves as a high-power voltage source for the MediPlas Reactor.

Is the MediPlas Reactor an ozone generator?

The MediPlas Reactor is more than a simple ozone generator. By feeding in different input gases, different output gases can be generated. In addition, the concentrations of the output gases can be adjusted by setting the energy, temperature and amplitude.

Which input gases can be fed into the MediPlas Reactor?

Oxygen, dry air and humid air can be blown into the MediPlas Reactor.

Which output gases are generated?

When oxygen is supplied, ozone with a high concentration is produced. When dry air is supplied, ozone and nitrogen oxides are produced. When humid air is supplied, ozone, nitrogen oxides and hydrogen peroxide are produced.

What happens by feeding humid air into the MediPlas Reactor?

The hydrogen peroxide concentration increases with increasing moisture content.

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