• Static Generators & electrodes

High-voltage generators and charging electrodes or charging bars from Simco-Ion

High voltage generators, generator bars & electrostatic electrodes

High voltage electrostatic generators, like the Simco CM5 charging generator, create a controlled static charge up to 60kV on a non-conductive material that will allow a temporary adhesion between 2 surface s with charges of opposite polarity. A high DC voltage (up to 60kV) can be safely produced and is carried to the emitters of an generator bar or electrode, where it is connected to an array of suitably designed emitter pins to generate a “corona”. A strong, ion-saturated electrical field around the single polarity high voltage points forces the material to a reference earth clinging the different surfaces together.

 

How does electrostatic charging work and how does a generator look like?

A static charging system consist of a high voltage generator and an electrode. The high voltage generator supplies the high voltage needed to create a static charge. This can vary from 3 to 60 kVolts. The charging electrode comes in different shapes to enable an optimum result for each specific application. Currently Simco-Ion high-voltage generators are used for the production of the facemask with types FFP1, FFP2 and FFP3 that are used against the spread of the Corona-virus. More on the physics side of electrostatic charging can be found here.

Different type of Generators

To chose the right generator you need to chose between a large variety of high-voltage generators the choice is mostly based on the space that you have available and the Voltage(power) that is needed to get the job done.

 

Different types of Static Generators

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Different types of charging electrodes

For the use of HV Static generators you will need a Pin or an electrode to create the "corona" field that enables the force to bind material These electrodes can consist of a single pin, like in the application of edge-pinning or multiple emitter-pins. The emitter pins are positioned within close proximity of a grounded surface or roller. For greater effect, a generator bar with emitter pins of the opposite polarity. The type of generator bar or charging bar is determined based on the application at hand. Besides the regular HDC generator bars, which are suitable for most common applications, Simco also developed one of the most powerful bars on the market today. The HDR generator bar is the robust bar which is especially developed as a static solution for industrial heavy duty and high-speed applications.

 

Types of Electrodes for Charging applications

Electrostatic Pinning 5 point
Pinner 5 point
Static pinning claw
Static pinning claw
charging bar HDC-HDR
charging bar HDC-HDR

How does charging work physically

The charging electrode is located opposite an earthed plate or roller. Because of the electrostatic field the material web will temporarily adhere to the reference earth.

There are also conditions without reference earth. Ions of different polarity attract each other, this causes an isolator (e.g. film) to adhere temporarily to a material with a different polarity, in this case an isolator as well.

Most powerfull principle. Negative Ions of top electrode pull positive ions from the bottom electrode with maximum power and glue-effect as a result.

 

Simco-Ion patented IML Solution

High-voltage generators from Simco-Ion generate static charges that can be used to pin labels tight against the inner mould surface during injection moulding. Finished product quality is greatly improved by this method. The label will not slip or change position in the mould. Simco-Ion’s patented IML charging method provides an easy way of constructing a charging electrode. It uses an anti-static foam material that provides a full contact with the label and even distribution of the electrostatic charge.

 

This simplified method of IML charging uses the anti-static foam material as a basis. Instead of applying the voltage directly to the foam electrode the label will be electro statically charged against the foam electrode. In the next step the label can be transferred into the mould.

Bipolar direct voltage

The unpleasant effects of static electricity are well known. People get shocks, materials cling together, a spark damages materials or even causes a fire. A electrostatic charge created by a High-Voltage generator from Simco-Ion can also be very useful ! Materials can be charged deliberately to make them bond temporarily. Static charge can be an invisible helping hand in your production process. This method is already used in many processes in various industries. Some examples are:

 

  • Block a stack of paper or magazines to prevent shifting during transport or packaging.
  • Creation of FFP3 facemasks during production.
  • Fix an address label to a brochure before the brochure is packed in a wrapping film.
  • Keep the last bag of a roll (ie.Garbage bags) fixed to the roll to make packaging in a carton easier
  • Bond a small section of a film during winding on a roll to prevent the roll from telescoping.

 

Many products we use daily are produced with the help of an electrostatic charge without us knowing it.

Various terms are used for the same technique, electrostatic charging, static bonding, static charging, static clinging or electrostatic gluing.

 

A perfect example is packaging of food products and many plastic products for domestic use. Many products are produced with the aid of a static charge. Instead of printing directly or placing a sticky label onto the product, the print is achieved with a pre-printed plastic label. The pre-printed label is positioned into the injection mould and kept in place by a static charge. This way the label will be moulded together with the product shape and come out as a finished product.

A spectacular application of static bonding is keeping together large objects. Stacks of brochures or flooring laminate can be held together with a static charge to prevent them from shifting during transportation. This demonstrates the enormous force that can be generated by an electrostatic charge.

Extraordinary, but not obvious applications of using static charge appear regularly. Applying a homogeneous static charge created by a high-voltage generator from Simco-Ion to a surface has a very positive effect in processes where fluids need to be dispersed across the surface. A common application is the production of DVD discs. Each DVD disc consists of two thin plastic layers that are glued to form the finished disc. A electrostatic charge is induced on one surface which causes the glue the disperse much more evenly.