Low-Pressure PlasmaPlasma system Tetra 1440
Modular plasma system for large and long components
The Tetra 1440 low-pressure plasma system, with a chamber volume of 1440 litres, has been specially developed for large components and high production volumes.
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Maximum flexibility thanks to a modular chamber design
The Tetra 1440 low-pressure plasma system has been developed for demanding industrial applications where standard systems reach their limits. With a chamber volume of 1440 litres and a modular vacuum chamber constructed from aluminium profiles, the system can be flexibly adapted to different component sizes and production requirements. The system is ideally suited for plasmacleaning, surface activation, plasma etching and plasma coating of large or long workpieces.
Depending on the application, the Tetra 1440 can be equipped with various control options. The full PC-based control system enables the documentation and archiving of all process parameters, as well as integration into higher-level production systems via an optional MES connection.
Thanks to its modular design, the system is particularly suitable for companies whose production processes are constantly growing or changing. Typical areas of application include the aerospace industry, the automotive sector, medical technology, specialised machinery manufacturing, semiconductor technology and electrical engineering
Cleaning
The Low-Pressure Plasma system Tetra 1440 offers solutions for ultra-precise cleaning of all surfaces, for every substrate, and for every post-treatment process. Plasma cleaning removes all organic residues without subjecting the component to chemical or thermal stress.
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Activation
Good surface wettability is a prerequisite for the adhesion of bonding partners during painting, gluing, printing, or bonding. Plasma activation using the Low-Pressure Plasma Tetra 1440 system creates polar bonding partners and increases the surface energy.
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Coating
The Low-Pressure Plasma Tetra 1440 system can also modify surfaces by applying a coating. Plasma coating can be used to deposit hydrophobic, hydrophilic, protective, or insulating layers of any kind.
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Etching
The plasma technology of the Low-Pressure Plasma Tetra 1440 system enables anisotropic and isotropic etching. This results in the nanostructuring of surfaces, which increases their surface area and improves adhesion.
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1440l chamber
The Low-Pressure Plasma Tetra 1440 system is equipped with a large chamber volume of 1440 litres, which is ideally suited to large industrial components. Furthermore, the chamber can be designed to be shorter or deeper in 500 mm increments. An aluminium chamber is available for this purpose, ensuring particularly safe and stable industrial processes. The generous chamber size allows for the simultaneous processing of complex or multiple components, making the Tetra 1440 ideally suited to industrial production processes and series production applications. Easy integration into existing production environments is facilitated by the option of two-part loading trolleys and an automatic door.
Electrode
Requirements are increasing as technology advances. With Diener electronic, companies benefit from a high level of investment security, as the Tetra 1440 system can be further developed to meet future requirements. Thanks to the flexible modular system, the choice of single- or multi-tier electrodes for the Tetra 1440 plasma system is determined by the specific application. For complex, larger components that take up a lot of space in the chamber, an electrode that ensures uniform treatment is recommended. For many small components arranged across several levels, multi-tier electrodes or a rotary drum electrode are installed to ensure uniform treatment in every application of the Tetra 1440 plasma system.
Industry 4.0
To meet the growing demands of Industry 4.0, Diener electronic offers the Low-Pressure Plasma Tetra 1440 system with an optional automatic door. This allows the plasma system to be quickly integrated into an MES and optimally incorporated into automated production lines. The option of automated loading and unloading reduces the need for manual intervention, thereby increasing process reliability and enabling reproducible processes. Through automation, the Tetra 1440 plasma system ensures efficient quality control.
Control
In industrial sectors with demanding production requirements, the control unit, when used in conjunction with a FULL PC running Windows IoT, is ideal. This ensures that the Low-Pressure Plasma Tetra 1440 system has process archiving, alarm lists, remote diagnostics and network connectivity. Process transparency and traceability form the basis for efficient and cost-effective production. A range of hardware configurations offers maximum flexibility for the processes carried out by the Tetra 1440 plasma system. The PI/PID pressure regulator enables pressure stabilisation, which ensures that processes are precisely reproducible at all times. With the Full PC control system, ongoing processes are displayed in a way that makes them easier to monitor, in greater detail and at a faster pace.
Technical data
Housing dimensions
Standalone
Control unit
Full PC (Windows 11 IoT Enterprise)
Vacuum chamber
Aluminium, Hinged door
W 1200 mm x H 1200 mm x D 1000 mm; Volume approx. 1440 liters
Optional: Depth modularly expandable in 500 mm steps
Generator
80.00 kHz | Power output 0 - 5000 W
Gas supply
MFC (Mass flow controller)
Electrode
Single-tier electrode
Multi-tier electrode
Pressure measurement
Pirani sensor
Capacity pressure gauge
Power supply
400 V | 16 - 125 A
Technical changes reserved.
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FAQ Frequently Asked Questions
What extensions are possible with the Tetra 1440?
With the Tetra 1440 from Diener electronic, extensions such as a rotary drum for bulk materials, roll-to-roll systems for virtually continuous films/textiles, or automatic doors for autonomous operation on the production line are usually possible. Get in touch: “We create solutions.”
What information do we need from you in order to provide you with a quote?
To provide a quotation for Diener electronic, we require component specifications such as dimensions, material, temperature sensitivity, as well as the type of process and planned quantities.
What connectivity options are available for the software control system on the Tetra 1440 system?
With its full PC control system, the Tetra 1440 plasma system from Diener electronic offers the following connection options, such as:
- higher-level control systems, e.g. via Profinet
- MES systems, e.g. via OPC UA
- Database connection via ODBC
Which surfaces can be activated using the Tetra 1440 plasma system?
The Tetra 1440 plasma system from Diener electronic can be used to activate the following surfaces: plastics, metals, glass, ceramics and textiles.
Which gases can be used with the Tetra 1440?
The following gases can be used in the Tetra 1440 and, more generally, in low-pressure plasma: O₂, N₂, Ar, ambient air, CO₂, H₂O vapour and forming gas
Can temperature-sensitive components be processed using the Tetra 1440?
Yes, as this is a cold plasma, the low-pressure plasma systems Tetra 1440 from Diener electronic are suitable for temperature-sensitive components.
What is the typical process temperature for the Tetra 1440 in the vacuum chamber?
With the Tetra 1440 from Diener electronic, the temperature is normally between room temperature and approximately 80 °C – depending on the component, chamber type, process time and load quantity. Higher temperatures can be achieved on request from Diener electronic using heating elements.
What is the typical pressure range usually found in the vacuum chamber of the Tetra 1440?
The typical pressure range of the Tetra 1440 is adjustable from 0.1 to 1.0 mbar, depending on the defined low-pressure plasma process.
Is there an alternative to hydrogen in the Tetra 1440 system?
Upon request to Diener electronic, a hydrogen generator or water vapour may be considered as an alternative to hydrogen for the Tetra 1440 system.
Are exhaust air filters required for the Tetra 1440?
Yes, all systems must be connected to a proper exhaust system, regardless of the type of gas used. Nitrogen oxides, exhaust gases, fine oil mist (from oil pumps), etc. are produced, which must not be inhaled; furthermore, the gases are often acidic, meaning they accelerate the rusting of surrounding parts, machinery and equipment.
What is the frequency of the GHz system Tetra 1440?
The generators for the GHz system Tetra 1440 operate at an ISM frequency of 2.45 MHz – comparable in intensity to that of a microwave. Please enquire about the safety guidelines for people with pacemakers.
Can the control software for the Tetra 1440 plasma system be adapted to meet our requirements?
On request, we at Diener electronic can customise the full PC control system for the Tetra 1440 series. Please do get in touch with us regarding this.
