Corona Systems

Surface functionalization for your production process

ESSENTIAL FEATURES OF SCANA CORONA TECHNOLOGY

CORONA SURFACE PROCESS

 

Corona system is used for functionalizing of surfaces of film webs for enhancing adhesion properties. The system consists of two main components, the Generator which supplies the electrical power and the Station where the corona treatment of the web takes place. Other components are the transformers for generating ignition voltage and fans for extraction or ventilation.
Physically, the corona discharge is a dielectric barrier electric discharge in the air at atmospheric pressure and therefore a plasma. The latter burns in about 2 millimetre wide gap between the corona electrode and the carrier roll. The film web to be treated is moved through this discharge area. The reactions taking place in the area of the corona discharge on the surface of the web make it more adhesion friendly.
The corona operation generates ozone which must be extracted. The exhaust air contains dust and aerosol of the ambient air as well as numerous degradation products of polymers and additive. During continuous operation these are deposited in significant amounts on the surfaces of the electrodes, their brackets, the insulators and panels of the electrode housing. The deposits build up over time, are crystallized and form electrically conductive deposits which can cause operational disruptions.

[Translate to English:] 3 Coronastationen mit Keramikelektroden
[Translate to English:] Coronastation, vorbereitet für Inertgasbetrieb
[Translate to English:] Coronastation mit Metallelektroden
[Translate to English:] Schmalbahnstation
[Translate to English:] Vorführanlage Coronabehandlung
[Translate to English:] Keramikelektroden in Einschubkassette

ABOUT THE SCANA CORONA SYSTEMS

LOW ELECTRODE SOILING THANKS TO THE EXTRACTION OF EXHAUST AIR OUTSIDE THE ELECTRODE SPACES

Contact between the impure exhaust air with the discharge electrodes is significantly reduced. The hall air is extracted next to the electrode pack and does not come
into contact with it. During the continuous operation the electrodes and the electrode housing remain essentially clean, the disruptions due to deposits
of degradation products are avoided, the maintenance costs are accordingly low.

SUPPLY AIR WITH COOLING AND CLEANING EFFECT

The rear electrode space is purged continuously with filtered air. The build up of deposits on the insulators and housing parts of the rear electrode space is avoided. The purge air then flows through the electrode pack, keeps it clean, cools it at the same time and extracts it via the extraction channels. The corona discharge heat is partly also transferred onto the material web. This can lead to micro wrinkles and partial back side treatment, which is disruptive in many cases. The cooling air of the electrodes cools the web right away so that its temperature increase can be controlled and remains in permissible range. The material is spared.

EFFICIENT OPERATION AND GUARANTEED EFFECTS

SCANA CORONA generators are highly reliable thanks to the use of components from well-known manufacturers. The components, in particular the high performance power amplifier, are low-loss. All important process parameters, including the effective power, are monitored continuously.
The extraction on the electrode housing is concentrated on the output gap, requiring lower blower power.
An energy-saving, power proportional extraction control can be optionally supplied.
The electrode supporting system is designed to be very solid and precise, so that the corona gap can be precisely adjusted in tenths of millimetre for optimal treatment effect.
SCANA CORONA uses wide ceramic and metal electrodes. The material under the discharge electrodes in the running direction has long dwell time.
High number of fine streamers build up. All these measures result in an optimisation of the effect, without increasing effective power.

PRECISION MECHANICS AND ELECTRICAL TECHNOLOGY MADE BY FGM GRADERT

As experienced machine builder and roll manufacturer with extensive know-how and high degree of vertical integration, FGM Gradert stands for excellent quality and precision. The corona stations and electrode packs are solid and produced with precise fits and high-quality fittings.
Corona support rolls, pressing and deflection rolls as well as all cubic parts are manufactured, coated and fully assembled by FGM Gradert.
Spare parts can be produced quickly if needed. Special customer requests such as e.g. food suitability of the roll surfaces or a stationary version as preferential section are no problem.
SCANA CORONA generators and high-voltage transformers are planed and assembled in-house. The programming of the control software is done by our electricians. Optional program parts, e.g. customised recipes or a power-proportional fan control are done at FGM Gradert.

NO OZONE LEAKAGE ON THE ELECTRODE SYSTEM

The ozone generated during the corona treatment in the electrode housing is partly hauled outside by the material web. The SCANA CORONA electrode systems are constructed such that the extraction is concentrated on the web discharge side. The ozone on the material web is fully extracted.

USE AT HIGH HUMIDITY

With many corona electrodes there is water condensation in the electrode housing in the event of high ambient air humidity, e.g. after a summer thunderstorm. This phenomenon triggers sliding discharges on the surfaces of the insulators and housing panels, resulting in faults and in worst case to operational disruptions. For these environmental conditions SCANA CORONA optionally offers continuous ventilation function in order to avoid condensation. The supply air can be additionally conditioned if needed.
A pneumatically operated, tight-closing throttle valve can be installed in order to prevent humidity condensation caused by inflowing outdoor air in the open exhaust channel when the extraction is switched off.

SYSTEM PROGRAM

SCANA CORONA systems are available for single-sided, double-sided and reciprocal treatment of various webs from e.g. PP, PE, PVC, PET, PA, paper and  pre-impregnated, metal and metallized films, foam films or non-woven materials. As standard, our station program includes rotating and parallels opening electrode systems and individual special construction. Depending on the application parameters we implement numerous options  such as, among others, pressing, expander or deflection rolls, roll drives, belt wheels for guided web infeed, sound-insulated housings, exhaust air purification, remote controls and special paint.