Think Clean Blog

Validating CO2 Tech Performance

Posted by Amanda Bunch on Apr 25, 2018 1:09:22 PM

Question: How do you know when something works really well?

Answer: When its performance can be validated in several different ways.

This holds true for CO2 technology. There are numerous ways to qualify the performance of our CO2 technology in your manufacturing operations.  For example, the following are just a few example metrological techniques that demonstrate how CO2 technology can be validated.

     DOWNLOAD CONTROLLED ENVIRONMENTS MAGAZINE PUBLISHED ARTICLE SEP 2012

   DOWNLOAD ADHESIVES MAGAZINE PUBLISHED ARTICLE JAN 2017

 

Product Cleanliness

Particles and Residues

Surface and substrate contamination such as flux residues, organics, particulate matter, outgassing residues, ionic residues, and laser and mechanical machining heat is addressed (uniquely) with this technology. Available CO2 processes include one or a combination of composite jet sprays, centrifugal liquid immersion, supercritical fluid extraction, and both vacuum and atmospheric plasma surface treatments.

 

Product Performance

Bond Strength and Surface Roughness

Advanced carbon dioxide (CO2) spray cleaning technology provides various methods for consistently preparing surfaces for bonding operations. Numerous spray, immersion, and plasma CO2 treatments are available which may be combined with advanced collaborative robotics. The inherent adaptability, performance, and economy of CO2 technology provides numerous and varying manufacturing benefits.

A non-contact surface analysis device and technique called Optically Stimulated Electron Emission (OSEE) is used to analyze surfaces to determine surface quality levels before and after CO2 spray cleaning. OSEE surface inspection technology is a great way to validate CO2 Composite Spray™ for surface preparation. This process is most suited for analyzing metallic surfaces. For most metallic surfaces, the cleaner the surface the higher the OSEE photocurrent measured. OSEE can measure inorganic as well as organic contamination present on surfaces. Using OSEE before and after cleaning with CO2 composite spray is an excellent analytical and SPC technique for bonding processes, among other manufacturing processes.

    DOWNLOAD IMAPS RAMP PRESENTATION APR 2014

 

Process Performance

Adaptability and Productivity

CO2 technology eliminates or significantly reduces both lean and green waste generation at the production operation level (source) by modifying manufacturing processes such as precision cleaning and machining. Because it is safe and dry, CO2 technology can integrate directly into manufacturing processes and tools to provide in-situ cleaning and/or thermal control. CO2 technology can be implemented in a variety of process configurations to meet the constraints of lean production layouts and product flow requirements, including direct integration into existing production lines and equipment where the surface contamination is being generated. CO2 is a safe and abundant compound that plays a very important role in many commercial and industrial applications. CO2 can be used in cleaning, cooling and machining applications. Many companies have implemented CO2-based cleaning technology and have realized improved productivity and a lower cost-of-operation of their production operations.

CO2 CleanTech represents a significant business opportunity to adapt production tools and operations to meet the challenges. The merging of green practices such as CO2 technology into manufacturing is delivering additional value in the form of less chemical, energy, labor, and water usage as well as the elimination of solid wastes, air and water pollution.


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    DOWNLOAD CO2 VALUE PROPOSITION PRESENTATION JUN 2017

 

Specialized Metrology

Compatibility and Sterility

CO2 technology can be used as a solid, liquid, supercritical fluid, and both atmospheric and low-pressure plasma. CO2 is useful as a spray treatment agent, immersion and extraction solvent, as well as in the form of many hybrid or combinational substrate processing possibilities. Applications include precision degreasing, departiculation, outgassing, precision drying, disinfection, surface modification and functionalization, cooling and lubrication, among many others.

 

 

 

 

 

Ready for next steps? Try our free CO2 Consultation.

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Topics: Surface Preparation, CO2 Cleaning, CO2 Precision Cleaning, contamination control, CO2 Composite Spray, CO2 Technology, CO2 Testing, CO2 Analysis, OSEE

3 Ways To Use CO2 Immersion

Posted by Amanda Bunch on Mar 12, 2018 8:31:00 AM

Precision cleaning requires CO2 technology that provides improved performance, productivity, environmental quality and economics, all while adapting to rapidly evolving device manufacturing technology. CO2 technology has been used primarily as a means for increasing the cleanliness of components, assemblies, tools and fixtures to increase both capacity and quality. However, arguably more significant, CO2 technology has proven itself to be a means for reducing the cost and improving the productivity of manufacturing high volume and high reliability products. In response to new manufacturing pressures, solvent-based cleaning processes have re-emerged to prevent malfunctions in high-reliability or high-power applications, necessitating a green process solution.

A precision cleaning technology called centrifugal CO2 cleaning combines unique centrifugal dry washing and rinsing processes using specially formulated high-boiling solvents such as citrus terpenes and paraffins with recycled carbon dioxide in a tunable cleaning solvent system.

Let's look at the 3 ways CO2 immersion is used and tested.

 

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    DOWNLOAD RUBBER WORLD MAGAZINE PUBLISHED ARTICLE SEP 2012

    DOWNLOAD KINETX TECH SPEC

 

1. Precision Cleaning

Precision cleaning trends caused a change in solvent cleaning practices in the 1990's. New environmental concerns and legislative agendas regarding climate change, water and energy conservation shaped the new precision cleaning imperatives for the future. Complex devices such as flip-chip assemblies, disk drives, parts with micro-machined features, composite materials, bioabsorbable polymers, and partially assembled devices had a cleaning need that could not be solved with traditional methods.

In the early 1990s, the first generation Centrifugal CO2 cleaning systems were introduced as an alternative to ozone-depleting substances. This process was adopted faster for high-tech industrial applications. This new process proved to be as good or better than comparable cleaning processes and overcame weak solvent power. Centrifugal CO2 cleaning technology provided significant improvements in productivity, environmental quality, and cost of ownership of their precision cleaning operations.

Liquid CO2 is more suited as a solvent for less complex contamination but very effective for penetrating complex substrate geometries. CO2 is also an excellent drying or rinsing agent (as a solvent) for more powerful washing agents such as a high-boiling solvent (HBS). Using this unique solvent scheme, a range of wash-rinse cohesion energies, solvent powers, viscosities and surface tensions can be employed to address many different types of challenging (and more general) device cleaning applications. CO2 technology offers manufacturers, component suppliers and assembly equipment OEMs new techniques to retool their factories and equipment for clean production.


2. Outgassing - Extraction

For outgas cleaning involving certain polymers and applications, an optimal vacuum degas step is employed to remove residual adsorbed CO2 gas. All CO2 process fluids are automatically transferred and recovered using an integrated fluids management and recycling subsystem.

Centrifugal CO2 systems combine centrifugation, ultrasonics, exclusive CO2-expanded and/or optional O3-loaded prewash agents, liquid carbon dioxide, and optional downstream plasma post-processing with energy-efficient fluids recycling and reuse in a single system.  This system is the most capable precision cleaning platform available today and uses only environmentally safe and non-toxic cleaning agents. The parts washing chamber is a top-loading basket centrifuge with a manual or automatic closure.  The system includes fluids distillation, re-circulating spray-under-immersion, and clean fluid storage.  

 

3. Reusable CO2

The CO2 expanded HBS wash system separates, cleans and recovers carbon dioxide, HBS and contaminants using phase separation and microfiltration. The recovered CO2 is transferred into both the gross rinse tank and final rinse tank for reuse. The system is capable of recovering more than 95% of the CO2 for reuse. Centrifugal CO2 cleaning is a great substitute for traditional solvent and aqueous processes with bio-based agents reduces pollution, conserves energy and eliminates manufacturing wastes.

 

Why Centrifugal CO2 Immersion Cleaning?

1. Fully developed cleaning technology that provides a number of unique process benefits.

2. 100% dry cleaning (and rinsing).

3. Bio-based cleaning chemistries.

4. Extremely low surface tensions and viscosities.

5. Solvent cleaning power control.

6. Reduces waste generation and operational costs by eliminating the need for water, waste-water treatment, water recycling and drying with a smaller footprint.

7. Environmental safety and lower energy demand.

8. Develops unique cleaning solutions for the most demanding substrate-contaminant combinations.

 

Ready for next steps? Try our free CO2 Consultation.

REQUEST A CO2 CONSULTATION

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Topics: Surface Preparation, CO2 Cleaning, CO2 Precision Cleaning, CO2 Immersion, CO2 Composite Spray, CO2 Technology, Centrifugal CO2

5 Tips For Maximizing Your CO2 Rental

Posted by Amanda Bunch on Jan 24, 2018 1:39:49 PM

CleanLogix offers, through its reseller partner Clean Imagineering, CO2 composite spray cleaning equipment rentals.  Renting provides the opportunity to test-drive our CO2 spray cleaning technology in the lab or on the production floor before you consider moving to the next step.  Develop proprietary cleaning processes for your parts cleaning applications confidentially in your own facility. 

Renting our equipment helps to create internal support and development of a CO2 champion that will insure successful adoption – from lab to production floor.  Invite your production, quality, environmental, and procurement associates to understand the mechanics and benefits of this technology.

The CleanLogix technical team is available to help you successfully develop your proprietary cleaning application and to understand the elements needed for production-scale equipment using the cleaning process you have developed.

Let's look at 5 tips to better maximize a CO2 composite spray equipment rental and ensure a productive and enjoyable testing experience.

 

VIEW CO2 TECHNOLOGY RENTAL PROGRAM: TRY BEFORE YOU BUY

 

1. Try Before You Buy

Most people test drive a vehicle before they buy. So why not test drive our CO2 technology before you purchase a system? The main benefits of renting are the small initial investment, ability to test various applications in-house, and discounts off the purchase price. 

Companies do not adopt new equipment and processes without testing first.  In this regard, CleanLogix offers two ways to achieve this: 1) In-house sample parts and analysis and 2) Cleaning equipment rentals. 

Renting can be the best way for companies to adopt new technology, allowing the lead process development engineer to demonstrate efficacy and benefits directly to all interested departments and colleagues.  Our team can work with you develop a test plan that provides the best chance of success.  Indeed, we have found that many of our customer success stories started with a rental for on-site R&D tests before making the transition to purchasing a system. Practice makes perfect and renting can determine the perfect product to meet your company's needs.

2. Get Consulted

REQUEST A CO2 CONSULTATION

With over 30 years of experience in the CO2 technology field, our team is ready to provide you with all the guidance you need to be successful in using our CO2 rental equipment. This program works well, particularly if you are new to the technology or have used different CO2 technology in the past.

The CO2 consultation program provides an introduction of CleanLogix, our various CO2 technologies, and commercial products we offer.  The consultation is a platform for us to learn about your cleaning challenges and what we think might help you.  Customers who engage with our team before renting or buying have a higher success rate than those that go into the process blindly and execute solo. All consultations are free, so why not take advantage!

A typical consultation takes between 45-60 minutes. We will cover a brief background of CleanLogix and then focus on your application.  Our discussion will range from your current cleaning application and challenges, to potential CO2 cleaning and contamination control options.  Specialty areas include build-clean and surface preparation for bonding applications. 

To get an idea of how the meeting will go, following are a few of our questions:

“Please tell us about your cleaning application and what you are looking to achieve using our CO2 technology?”

“Please tell us a little about your current cleaning system and process?”

“Do you have an active budget for this project?”

"How soon are you looking to solve your cleaning problem?”

“Now that we have heard about and understand your cleaning application and cleanliness challenge, we will provide a detailed recommendation as a follow-up.”

“Here are what probable next steps should be based on your timing and budget.”

We are here to help you be successful using CO2 technology. We want your experience with our company to be informative, actionable, and a return on your investment.

3. Plan for Success

To achieve any goal you must have a plan that guides you to the desired result. The main reason customers seek our technology is because they are looking to solve a problem that cannot be solved productivity or economically using an alternative technology, for example aqueous cleaning.  As evidenced by our global partnership with Hitachi High-Tech, we are recognized experts in CO2 precision cleaning and pride ourselves on having the most experience and knowledge as compared to our competitors.  Over the past 30 years, we have solved hundreds of unique cleaning problems for companies representing nearly every precision product manufacturing market and industry.

We collaborate with our partner Clean Imagineering (www.cleanimagineering.com) who specializes in laboratory samples testing, rentals, demos and testing/analysis. We don’t ship you the system and say good luck! Before you begin your trials you will be given a test plan, operation and maintenance manual, and a Quick-Start operations set-up training video. In addition, you have the option to have Clean Imagineering test samples in-house and provide you with a concise test and analysis report.  We want you to be completely informed and confidant that the system you want to rent will resolve your cleaning challenge.  The CleanLogix and Clean Imagineering teams are here to answer your questions and work through any issues step by step.

Below is an example test plan and analytical report:

The sample test plan outlines the procedure - both cleaning and analytical testing - that will be performed for your application. If it is decided during the consultation that the testing should be performed by our in-house laboratory team, we will provide you with a final laboratory report in conjunction with the plan.

4. Apply What You Have Learned

If we achieve success during in-house test trials (yes, it worked!) now what? It would be beneficial to perform a simulated production line or tool test using our rental equipment. Step 1 validates efficacy of our cleaning technology with regards to your application and Step 2 validates that this cleaning technology will perform in production (with proper scale-up and facilities).  If the demo equipment trial meets and/or exceeds expectations then our scaled production systems will do even better.

However, with that said it is important to keep in mind that the rental systems have limited capacity and are used systems. If the qualification gets to the point of production trial, then it would be the time to start looking into purchasing a production capable system.

5. Take Credit

Rentals are loaned out for one to three months at a time. Make the best use of your rental time to decide if this technology works for your application. One of the greatest advantages for renting before buying is that if you rent a unit for a minimum of two months, you will be credited the two month rental fees off the total purchase price.

Renting allows a potential customer to test the technology in a short time period with little investment and provides the qualitative results to procure a purchase approval.

 

Ready for next steps? Try our free CO2 Consultation.

REQUEST A CO2 CONSULTATION

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Topics: Surface Preparation, CO2 Cleaning, CO2 Precision Cleaning, CO2 Composite Spray, CO2 Technology, CO2 Rentals, Rent2Clean

Why Is Surface Preparation Something To Care About?

Posted by Amanda Bunch on Jun 22, 2017 9:54:13 PM

You may be asking yourself what does surface preparation have to do with CO2?

Appropriate surface preparation is the essential first step in providing consistent and reliable adhesive or cohesive bond strength.  In preparation of bonding surfaces, precision cleaning is required to achieve a high degree of surface cleanliness. Surface cleanliness is the absence of foreign materials deposited on bonding surfaces.

Conventional surface treatment options for joining substrates pose different constraints in terms cost of ownership, environmental compliance, and performance. Carbon dioxide (CO2) based processing alternatives offer an effective, eco-friendly and robust platform for preparing many types of substrates surfaces for numerous medical, aerospace, automobile, ophthalmic and microelectronic bonding applications.

 

   DOWNLOAD SAMPE JOURNAL PUBLISHED ARTICLE NOV/DEC 2015

Conventional Surface Preparation

How Clean is Clean?

Removing contaminants such as fingerprints, particles, manufacturing process residues, vapors, machining oils, loosely adhering oxides and other surface contaminant layers are crucial for creating a surface for bonding.

Conventional industrial cleaning techniques pose various constraints that allow for product damage, contamination, materials wastes and not many are adaptable to automated manufacturing tools. Bonding technologies are numerous and include: adhesive bonding, mechanical fastening, laser welding, soldering, brazing, acoustic bonding, diffusion bonding, isothermal solidification bonding, transient liquid phase bonding, exothermic bonding, dip coating and thermal spray coating.

Hence, there is a need to have a more comprehensive surface treatment process that can address contamination challenges using one method as opposed to secondary treatments.

 

The CO2 Factor

Why is bonding essential?

There are various industries that require strong joints or durable surface adherents such as paints and coatings that can survive challenging environments such as pressure, strain, heat, cold, UV, ozone, steam, moisture and the human body. CO2 surface treatment technology provides robust bond line surface preparation using numerous singular and hybridized treatments which are completely dry, selective, safe for the environment and easily adapted or integrated with new and existing manufacturing processes, tools, lines and automation.

 

    DOWNLOAD IMAPS RAMP PRESENTATION APR 2014

 

Manufacturing a strong bond

Manufacturing a strong bonding surface requires three aspects:

1. Maximize mechanical interlocking - increase the surface roughness in order to physically anchor bond between adhesive and surface.

2. Matching cohesion energy - degree of cohesion energy matches the adhesive with surface to create a highly wettable bond.

3. Increasing surface absorption and reactivity - surfaces should have sites that are polar or contain chemistries for the adhesive reaction.

CO2 Surface Treatment Technology

Carbon Dioxide (CO2) based surface treatment technology can manufacture a consistent and reliable bond surface and address the various limitations of conventional cleaning and modification processes for bonding. 

 Precision CO2 cleans surfaces to remove hydrocarbon and silicone oil films, particles, and loose oxide layers, provides selective spray or bulk immersion treatments and pre-cleans surfaces for more uniform and effective atmospheric plasma surface activation.

 

 

   DOWNLOAD ADHESIVES MAGAZINE PUBLISHED ARTICLE JAN 2017

 

There are three CO2 processes that precision clean surfaces for bonding:

  1. CO2 Composite Spray Treatments - CO2 composite sprays provide precise control of spray cleaning energy both mechanical scouring and chemical cleaning power. CO2 composite sprays are very useful for delicate substrate surfaces such as thin metallic or polymeric coatings, or surfaces containing fragile mechanical features. 
  2. Centrifugal CO2 Immersion-Extraction Treatments - Centrifugal CO2 immersion treatment techniques utilize liquid or supercritical CO2 to remove both external surface and internal subsurface contaminants and are also used in cooperation with other dry techniques such as UV/Ozone, vacuum plasma and eco-friendly additive chemistries.
  3. CO2 Hybrid Treatments - the surface scouring and solvent cleaning actions of a CO2 composite spray are used in cooperation with atmospheric plasma CO2 to form a process called CO2 particle-plasma cleaning. The CO2 composite spray controls surface temperature and cleanliness working with plasma to simultaneously remove debris and excess heat from the treated surface.

 

Ready for next steps? Try our free CO2 Consultation.

REQUEST A CO2 CONSULTATION

Read More

Topics: Surface Preparation, CO2 Cleaning, CO2 Technology, advice about removal

CO2 Tech Pioneers

We set the bar

For over the past 30 years, CleanLogix LLC has been the forerunner of CO2 technology exploring all facets and propelling technological evolutions. Our technology portfolio is the only of its kind, offering a breath and depth of CO2 spray, immersion and particle-plasma patents that has in turn created multiple product platforms.

Remember:

  • Over 30 years experience
  • CO2 eliminates manufacturing wastes
  • CO2 is the solution for your contamination challenges

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