Plasma treatment machines are revolutionizing the wire and cable industry in several ways. Their impacts can be noticed in how certain basic processes are run in the telecommunications, automotive, and electronics industries.
Plasma treatment helps ensure effective surface modification of wire and cable surfaces to improve their reliability, durability, and performance.
Plasma treatment machines leverage material surface chemistry to prepare wire and cable surfaces for other applications. In this article, we look at how plasma treatment machines transform the wire and cable industry.
Understanding Plasma Treatment in the Wire & Cable Industry
Plasma treatment involves subjecting the surface of wires to plasma. The resulting plasma, in turn, produces reactive photons, ions, and radicals that activate the surface modification of the target material.
The change in the material surface’s characteristics helps activate the surface for other applications, such as etching and coating.
This technology is highly appreciated in the cable and wire industry because it increases the wet capacity of the wire, which makes it more ink-friendly.
Plasma treatments exist in various types, including atmospheric plasma treatment, corona treatment, flame plasma, etc. The application of these plasma treatment methods has gained widespread recognition in the wire and cable industry.
Applications of Plasma Treatment in the Wire & Cable Industry
Plasma treatment applications are becoming more prevalent in the wire industry due to their invaluable benefits. Here, we examine these various applications in brief;
Surface activation for enhanced coating and insulation adhesion
Surface activation has become necessary as an effective method for improving coating and insulation adhesion for wires. This pretreatment technique has significantly enhanced wire durability.
Some of the benefits of plasma treatment in surface activation include the prevention of delamination, improved bonding, and better performance. These benefits increase the durability of wires and cables.
Surface cleaning and contaminant removal
The presence of contaminants on material surfaces can decrease the efficiency of coating and other similar applications on such surfaces. Plasma cleaning removes contaminants and impurities from material surfaces by exposing such materials to plasma.
Plasma treatment has become highly sought after in the wire and cable industry because it effectively removes dust, oil, and other impurities from wire surfaces. This has helped improve extrusion and coating quality in such industries.
The overall benefits of this surface cleaning technique are improved electrical performance, enhanced product quality and reduced defects.
Etching for improved bonding of layers
Plasma treatments alter the properties of a target surface so it can bond more effectively to other layers. Applying adhesive solutions on wires without surface cleaning has proven to be very inefficient.
Plasma cleaning helps to modify wire surfaces to enhance the bonding of other layers used for protection and conduction. Plasma-treated wire surfaces can bond more to other layers.
Specific Products in the Wire & Cable Industry With Plasma Treatment Applications
Plasma treatment applications are currently used to improve the quality of a variety of products in the wire and cable industry. We will explore these products in this section:
Electrical wires
Plasma cleaning is transforming the manufacturing of wires by ensuring that insulation adhesion is improved. Insulation is one property that will determine the lifespan of a wire.
Generally, plasma cleaning in the wire industry contributes to improved performance and longer lifespan for wires.
Coaxial cables
Plasma treatment machines have also been found to be extensively used in the manufacture of high-quality coaxial cables. This surface treatment method ensures effective surface activation, allowing for better shielding and better bonding of other outer layers.
Coaxial cables that have undergone surface cleaning perform better than untreated cable surfaces in the area of signal transmission quality. This is so because plasma-treated cables are known for their reduced loss of power as signal moves from one end to the other.
Fiber optic cables
Plasma treatment technologies are working wonders in this industry in the cleaning and activation of glass fibers and coatings.
Fiber optic cable manufacturers leverage this technology to increase signal clarity and protect cables from environmental hazards. Also, codes on cable surfaces can last longer when they are exposed to plasma cleaning.
Automotive cables
The automotive cable manufacturing industry is also enjoying its share of plasma treatment technologies. This tech efficiently ensures that insulation adhesion and protective coatings bond properly on cable surfaces.
Plasma cleaning brings several benefits to this industry, such as improved electrical contacts, advanced material treatments, reduced defects, and ensuring that materials last their lifespan even when under mechanical stress.
Telecommunication cables
Plasma treatment machines are used to remove impurities and improve mechanical properties of telecommunication cables. This cleaning method is perfect for preparing telecommunication cables for coating and assembly.
Some of the numerous benefits offered by plasma treatment in the manufacturing of telecommunication cables include enhanced reliability of data transmission and longer lifespan.
Power cables
Plasma cleaning is proving to be an excellent technique for improving sheath bonding and insulation in manufacturing power cables.
This application has enabled power cables to be used safely in high-voltage scenarios. Cable performance is also enhanced as a result of this treatment method.
Specialty cables
Specialty cables, such as those employed in the robotics, aerospace, and marine industries, are also subjected to plasma cleaning before they are deemed suitable for other applications.
This technology has made it possible for specialty cables to be deployed in the most challenging environments and conditions. Passing specialty cables through plasma enhances their resistance to water, chemicals, and other unfavorable elements.
Cable markings and printing
Cable markings and printing are just as important as other processes in the industry where cables are manufactured. So, cable markings and printings must be done effectively. Plasma treatment can improve how inks adhere on a cable surface. This is necessary to improve labeling.
With proper markings, cables can be correctly identified to ensure they are used in line with necessary regulations and compliance policies. And the markings can remain on the wires for as long as possible.
Benefits of Plasma Treatment in the Wire & Cable Industry
The benefits of plasma treatment processes are quite numerous in the wire and cable industry. Plasma cleaning methods are a game changer in improving insulation and coating adhesion for wires and cables. Products have become more reliable, as it reduces the percentage of product defects in the industry.
Another priceless advantage of plasma treatments is their eco-friendly attribute, which is completely devoid of any harmful chemicals. Such surface cleaning methods are preferred in a number of industries because of their zero-negative impact on the environment.
Finally, this treatment process contributes to increased productivity in the said industry. This is achieved by reducing the possibility of reworking a wire or cable. Products are manufactured once, translating to increased production efficiency.
Things To Consider Before Choosing a Plasma Treatment Machine for Wire & Cable Applications
Finding the right plasma treatment machine is vital for optimizing plasma treatment in wire and cable applications. As a potential investor, it is crucial to consider certain key factors that can influence the efficiency of every plasma treatment process.
Evaluate the kind of wires or cables you intend to have their surfaces treated. Establish the extent of the surface modification. In other words, you need to know the exact surface characteristics you hope to achieve.
It’s also important to decide on the quantity of production. This is necessary because different plasma treatment machines are designed to handle different production scales.
Plasma treatment machines designed for the wire and cable industry possess a variety of features that make them suitable for different applications. These machines can also be customized on-demand to suit special business needs.
Future Trends in Plasma Treatment for the Wire & Cable Industry
The demand for more efficient bonding in the wire and cable industry has resulted in several breakthroughs in R&D. Today, plasma technologies are leading the pack of surface treatment techniques.
Future innovations in the plasma world are meant to become more eco-friendly and more suitable for high-speed data cables. Some of the areas likely to experience tremendous growth due to plasma technology innovations are vehicle cables, 5G telecommunications, and renewable energy cables.
Conclusion
The widespread use of plasma treatment machines in the manufacturing of wire & cable has certainly impacted product quality a great deal.Plasma treatment has proven to be a superior surface treatment technology since it benefits users, manufacturers, and the environment. At Fari Plasma, you can choose the right solution for your business from our suite of plasma treatment machines.
