14.01.2010<br />Page 1<br />PLASTIC WELDINGwithLASER SYSTEMS<br />Distributed in the UK by:<br />
14.01.2010<br />Page 2<br /><ul><li>Basics
Concepts
Examples</li></ul>Material requirements:<br /><ul><li> Top part laser-transparent material
 Bottom part laser-absorbent material
 Compatible materials
 Melt Temp
 Chemical Compatibility </li></ul>Transparent joining part<br />Welding seam<br />Lasers radiation<br />vs.<br />Process r...
 Pressure
 Clear access for laser</li></ul>Melt zone<br />Absorbing joining part<br />Laser Transmission Welding<br />
14.01.2010<br />Page 3<br /><ul><li>Basics
Concepts
Examples</li></ul>Transparent joining part<br />Welding seam<br />Lasers radiation<br />vs.<br />Melt zone<br />Absorbing ...
14.01.2010<br />Page 4<br /><ul><li>Basics
Concepts
Examples</li></ul>IR<br />IR<br />d<br />d<br />IL<br />IL<br />IT<br />dopt  d<br />dopt &gt;&gt; d<br />Absorption Char...
 volume-absorption        dopt    d	 heating across the whole thickness
 surface-absorption  			dopt << d	 near surface heating</li></ul>d<br />IR<br />IT<br />IL<br />dopt&lt;&lt; d<br />
14.01.2010<br />Page 5<br /><ul><li>Basics
Concepts
Examples</li></ul>Laser<br />Lasers in material processing <br />HPDL*= high power diode laser	<br />properties of HPDL (d...
14.01.2010<br />Page 6<br /><ul><li>Basics
Concepts
Examples</li></ul>Weldable Materials<br /><ul><li>Thermoplastics ~  Amorphous and semi-crystalline polymers (like - like) ...
ABS, COC, PA, PBT, PC, PE, PMMA, PP, PS, SAN, ...
Combinations of different but compatible thermoplastics include:
PMMA-ABS, ABS-PC, ABS-SAN, PMMA-PC….
Upcoming SlideShare
Loading in …5
×

Laser Transmission Welding of Polymers

1,583
-1

Published on

Introduction to Laser Transmission welding of Polymer via Leister Laser Systems and Horizon Instruments

Published in: Technology
0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total Views
1,583
On Slideshare
0
From Embeds
0
Number of Embeds
1
Actions
Shares
0
Downloads
73
Comments
0
Likes
0
Embeds 0
No embeds

No notes for slide

Laser Transmission Welding of Polymers

  1. 1. 14.01.2010<br />Page 1<br />PLASTIC WELDINGwithLASER SYSTEMS<br />Distributed in the UK by:<br />
  2. 2. 14.01.2010<br />Page 2<br /><ul><li>Basics
  3. 3. Concepts
  4. 4. Examples</li></ul>Material requirements:<br /><ul><li> Top part laser-transparent material
  5. 5. Bottom part laser-absorbent material
  6. 6. Compatible materials
  7. 7. Melt Temp
  8. 8. Chemical Compatibility </li></ul>Transparent joining part<br />Welding seam<br />Lasers radiation<br />vs.<br />Process requirements:<br /><ul><li> Good thermal contact
  9. 9. Pressure
  10. 10. Clear access for laser</li></ul>Melt zone<br />Absorbing joining part<br />Laser Transmission Welding<br />
  11. 11. 14.01.2010<br />Page 3<br /><ul><li>Basics
  12. 12. Concepts
  13. 13. Examples</li></ul>Transparent joining part<br />Welding seam<br />Lasers radiation<br />vs.<br />Melt zone<br />Absorbing joining part<br />Laser Transmission Welding<br />
  14. 14. 14.01.2010<br />Page 4<br /><ul><li>Basics
  15. 15. Concepts
  16. 16. Examples</li></ul>IR<br />IR<br />d<br />d<br />IL<br />IL<br />IT<br />dopt  d<br />dopt &gt;&gt; d<br />Absorption Characteristics<br />Joining part:<br /><ul><li> “no” absorption dopt >> d  “no“ heating
  17. 17. volume-absorption dopt  d  heating across the whole thickness
  18. 18. surface-absorption dopt << d  near surface heating</li></ul>d<br />IR<br />IT<br />IL<br />dopt&lt;&lt; d<br />
  19. 19. 14.01.2010<br />Page 5<br /><ul><li>Basics
  20. 20. Concepts
  21. 21. Examples</li></ul>Laser<br />Lasers in material processing <br />HPDL*= high power diode laser <br />properties of HPDL (diode laser)  • high efficiency <br /> •compact<br /> • low-maintenance/ high life time<br />• low beam intensity<br />
  22. 22. 14.01.2010<br />Page 6<br /><ul><li>Basics
  23. 23. Concepts
  24. 24. Examples</li></ul>Weldable Materials<br /><ul><li>Thermoplastics ~ Amorphous and semi-crystalline polymers (like - like) materials welded successfully:
  25. 25. ABS, COC, PA, PBT, PC, PE, PMMA, PP, PS, SAN, ...
  26. 26. Combinations of different but compatible thermoplastics include:
  27. 27. PMMA-ABS, ABS-PC, ABS-SAN, PMMA-PC….
  28. 28. Thermoplastic Elastomers:
  29. 29. Thermoplastic Elastomer to Thermoplastic Elastomer
  30. 30. Thermoplastic Elastomer to non-elastomeric thermoplastics
  31. 31. Colour-combination possibilities:
  32. 32. Black - Black (special non-carbon colouring in one part)
  33. 33. Transparent – transparent (with addition of “clearweld”)
  34. 34. Other colours with special pigments</li></li></ul><li>14.01.2010<br />Page 7<br /><ul><li>Basics
  35. 35. Concepts
  36. 36. Examples</li></ul>Welding Seam Design<br />
  37. 37. 14.01.2010<br />Page 8<br /><ul><li>Basics
  38. 38. Concepts
  39. 39. Examples</li></ul>Design Considerations<br />Weldability of Material<br />Material A and B are based on the same material (PC with PC / ABS with ABS....)<br />Material A and B are made of different but compatible materials (PMMA with ABS, PC with PBT.............)<br />Optical properties of the Material is Suitable for Laser Transmission Welding?<br />Material A - transparent to laser radiation (e.g. clear material)<br />Material B - absorbs the laser radiation (e.g. Contains 1% Carbon Black)<br />Dimensions and shape of part and the welding seam are designed laser compatible?<br />Accessibility for laser, planarity, possibility to apply pressure?<br />
  40. 40. 14.01.2010<br />Page 9<br /><ul><li>Basics
  41. 41. Concepts
  42. 42. Examples</li></ul>Mask welding<br />Globo welding<br />Welding Concepts<br />Contour welding<br />Simultaneous welding<br />Quasi-simultaneous welding<br />Radial welding<br />
  43. 43. 14.01.2010<br />Page 10<br /><ul><li>Basics
  44. 44. Concepts
  45. 45. Examples</li></ul>Contour Welding<br />Contour welding<br /><ul><li> Spot laser guided by X-Y Axis
  46. 46. Highly Flexible
  47. 47. Simple Weld Design
  48. 48. Ideal for Quick Changeover</li></li></ul><li>14.01.2010<br />Page 11<br /><ul><li>Basics
  49. 49. Concepts
  50. 50. Examples</li></ul>Simultaneous Welding<br /><ul><li>Optic element used to form laser
  51. 51. One shot welding of weld seam
  52. 52. No relative movement
  53. 53. Short process times</li></li></ul><li>14.01.2010<br />Page 12<br /><ul><li>Basics
  54. 54. Concepts
  55. 55. Examples</li></ul>Quasi-Simultaneous Welding<br />Quasi-simultaneous welding<br /><ul><li> Mirrors guide laser over weld seam
  56. 56. High flexibility
  57. 57. Welding with displacement
  58. 58. Gap bridging possible</li></li></ul><li>14.01.2010<br />Page 13<br /><ul><li>Basics
  59. 59. Concepts
  60. 60. Examples</li></ul>Mask welding<br />Mask Welding<br /><ul><li>Line Beam Laser and Mask
  61. 61. Large areas and fine lines</li></ul>• Complex contours and shapes<br /><ul><li> Protection of sensitive parts</li></li></ul><li>14.01.2010<br />Page 14<br /><ul><li>Basics
  62. 62. Concepts
  63. 63. Examples</li></ul>Radial Welding<br /><ul><li> Radial radiation
  64. 64. No rotation of part
  65. 65. Short process times
  66. 66. Ideal for welding axially symmetric / Cylindrical
  67. 67. Push fit</li></ul>Radial welding<br />
  68. 68. 14.01.2010<br />Page 15<br /><ul><li>Basics
  69. 69. Concepts
  70. 70. Examples</li></ul>Globo welding<br />Globo Welding<br /><ul><li>Dynamic Clamping
  71. 71. Simple Joining Geometry
  72. 72. Continuous Welding
  73. 73. Ideal for 3-dimensional and large parts</li></li></ul><li>14.01.2010<br />Page 16<br /><ul><li>Basics
  74. 74. Concepts
  75. 75. Examples</li></ul>Contour welding<br />Laser Transmission Welding<br />Advantages of laser welding:<br /><ul><li> high precision
  76. 76. high strength
  77. 77. minimal mechanical stress
  78. 78. minimal thermal stress
  79. 79. no damage to electronic components
  80. 80. simple joining geometry
  81. 81. low tool wear
  82. 82. emission free
  83. 83. particulate free
  84. 84. no consumables (adhesive/fasteners)
  85. 85. joining of elastomers</li></ul>Globo welding<br />
  86. 86. 14.01.2010<br />Page 17<br /><ul><li>Basics
  87. 87. Concepts
  88. 88. Examples</li></ul>Origin: IMM<br />Origin: ILT<br />Origin: Eppendorf<br />Origin: Eppendorf<br />Mask welding<br />Requirement: welding of small structures (micro fluidics) changeable width of welding seam<br />Method: line-beam-laser and structured mask<br />Mask welding<br />
  89. 89. 14.01.2010<br />Page 18<br /><ul><li>Basics
  90. 90. Concepts
  91. 91. Examples</li></ul>Contour welding<br />Requirement:extremely flexible with excellent welding results<br />Method:spot optic with moving axis<br />Contour welding<br />
  92. 92. 14.01.2010<br />Page 19<br /><ul><li>Basics
  93. 93. Concepts
  94. 94. Examples</li></ul>Simultaneous welding<br />Requirement:short-time process<br /> no relative motion mass production<br />Method:laser beam is formed and guided by static optical elements<br />Simultaneous welding<br />
  95. 95. 14.01.2010<br />Page 20<br /><ul><li>Basics
  96. 96. Concepts
  97. 97. Examples</li></ul>Quasi-simultaneous welding<br />Requirement:no relative motion<br /> flexible like contour welding<br /> short time process like simultaneous welding<br />Method:two-mirror-scanner<br />Quasi-simultaneous welding<br />
  98. 98. 14.01.2010<br />Page 21<br /><ul><li>Basics
  99. 99. Concepts
  100. 100. Examples</li></ul>Globo welding<br />Requirement:welding of 3D components, large areas or continuous-feed applications<br /> flexible like contour welding<br />Method: spot optic combined with a dynamic clamping device<br />Globo welding<br />Quelle: ILT<br />
  101. 101. 14.01.2010<br />Page 22<br /><ul><li>Basics
  102. 102. Concepts
  103. 103. Examples</li></ul>Radial welding<br />Requirement: welding of rotationally symmetrical components without relative motion<br />Method: special optics and conical mirror<br />Radial welding<br />Photo: Leister, by courtesy of comp. Rasmussen, Maintal (Germany)<br />
  104. 104. 14.01.2010<br />Page 23<br /><ul><li>Basics
  105. 105. Concepts
  106. 106. Examples</li></ul>Micro pump<br />Requirement: welding of small structures (micro fluidics) changeable width of welding seam<br />Method: line-beam-laser and structured mask<br />Mask welding<br />Material:<br />PC transparent / <br />PC black<br />Specifications:<br /><ul><li> permeability
  107. 107. preservation of canal profile
  108. 108. canal width down to 100 µm
  109. 109. short processing time (3 seconds)</li></ul>Photo: Leister, by courtesy of IMM, Mainz (D)<br />
  110. 110. 14.01.2010<br />Page 24<br /><ul><li>Basics
  111. 111. Concepts
  112. 112. Examples</li></ul>Mixer-component<br />Requirement: welding of small structures (micro fluidics) changeable width of welding seam<br />Method: line-beam-laser and structured mask<br />Mask welding<br />Material:<br />PC nature / <br />PC black<br />(both structured)<br />Specifications:<br /><ul><li> permeability
  113. 113. preservation of 3D channel profile
  114. 114. channel width down to 130 µm,
  115. 115. overall size 35 x 40 x 4 mm</li></ul>Origin: FhG-ICT<br />
  116. 116. 14.01.2010<br />Page 25<br /><ul><li>Basics
  117. 117. Concepts
  118. 118. Examples</li></ul>Gas-Analyzing-System<br />Requirement:extremely flexible with excellent welding results<br />Method:spot optic and axis system<br />Contour welding<br />Material:<br />ABS natural / <br />ABS black<br />Specifications:<br /><ul><li> overall-size: 250x200x15 mm3
  119. 119. welding seam length: approx. 5000 mm
  120. 120. welded on both sides
  121. 121. preservation of channel profile</li></ul>Photo: Leister, by courtesy of comp. Testo (Germany)<br />
  122. 122. 14.01.2010<br />Page 26<br /><ul><li>Basics
  123. 123. Concepts
  124. 124. Examples</li></ul>Electronic Key<br />Requirement:extremely flexible with excellent welding results<br />Method:spot optic and axis system<br />Contour welding<br />Material:<br />PA laser transparent black<br />PA black<br />Specifications:<br /><ul><li> impermeability
  125. 125. no damage to electronics
  126. 126. no melting bulge</li></ul>Photo: FHG - ILT<br />
  127. 127. 14.01.2010<br />Page 27<br /><ul><li>Basics
  128. 128. Concepts
  129. 129. Examples</li></ul>Compensation tank <br />Requirement:extremely flexible with excellent welding results<br />Method:spot optic and axis system<br />Contour welding<br />Material:<br />PA 6 GF 30 nature <br />PA 6 GF 30 black<br />Specifications:<br /><ul><li> permeability
  130. 130. no contamination (particles)</li></ul>Photo: FHG - ILT<br />
  131. 131. 14.01.2010<br />Page 28<br /><ul><li>Basics
  132. 132. Concepts
  133. 133. Examples</li></ul>Electronic housing<br />Requirement:extremely flexible with excellent welding results<br />Method:spot optic and axis system<br />Contour welding<br />Material:<br />PC laser transparent black<br />PBT GF 30 black<br />Specifications:<br /><ul><li> permeability
  134. 134. No damage to electronic components</li></ul>Photo: Leister, by courtesy of comp. Elektra, Schalkau (Germany)<br />
  135. 135. 14.01.2010<br />Page 29<br /><ul><li>Basics
  136. 136. Concepts
  137. 137. Examples</li></ul>Optical Sensor<br />Requirement:short-time process<br /> no relative motion mass production<br />Method:laser beam formed and guided by optical elements<br />Simultaneous welding<br />Material:<br />PMMA transparent red<br />PC black<br />Specifications:<br /><ul><li> no optical distortion
  138. 138. no contamination (particles)
  139. 139. pressure (> 12 bar)
  140. 140. permeability </li></li></ul><li>14.01.2010<br />Page 30<br /><ul><li>Basics
  141. 141. Concepts
  142. 142. Examples</li></ul>Housing Flow-Sensor<br />Requirement:short-time process<br /> no relative motion mass production<br />Method:laser beam formed and guided by optical elements<br />Simultaneous welding<br />Material:<br />PMMA natural <br />ABS grey<br />Specifications:<br /><ul><li> no contamination (particles)
  143. 143. preservation of electronics and chips</li></li></ul><li>14.01.2010<br />Page 31<br /><ul><li>Basics
  144. 144. Concepts
  145. 145. Examples</li></ul>Display window<br />Requirement:short-time process<br /> no relative motion mass production<br />Method:laser beam formed and guided by optical elements<br />Simultaneous welding<br />Material:<br />PC nature <br />PC black<br />Specifications:<br /><ul><li> permeability
  146. 146. no optical distortion </li></li></ul><li>14.01.2010<br />Page 32<br /><ul><li>Basics
  147. 147. Concepts
  148. 148. Examples</li></ul> Demo (Fair: K 2004)<br />Requirement:short-time process<br /> no relative motion mass production<br />Method:laser beam formed and guided by optical elements<br />Simultaneous welding<br />Material:<br />PC nature / PC black<br />
  149. 149. 14.01.2010<br />Page 33<br /><ul><li>Basics
  150. 150. Concepts
  151. 151. Examples</li></ul>Camshaft sensor<br />Requirement: welding of rotationally symmetrical components without relative motion<br />Method: two-mirror-scanner and conical mirror<br />Radial welding<br />Material:<br />PA 66 GF 30 laser transparent black<br />PA 66 GF 30 black<br />Specifications:<br /><ul><li> permeability
  152. 152. no contamination (particles)
  153. 153. protection of electronic parts / sensors</li></ul>Photo: Leister, by courtesy of comp. Delphi Automotive, Luxemburg<br />
  154. 154. 14.01.2010<br />Page 34<br /><ul><li>Basics
  155. 155. Concepts
  156. 156. Examples</li></ul>Automotive lighting <br />Requirement:welding of 3D, large-area or endless components<br /> flexible like contour welding<br />Method: spot optic combined with a dynamic clamping device <br />Globo welding<br />Material:<br />PMMA transparent / <br />ABS black<br />Specifications:<br /><ul><li> no thermal and mechanical stress (Electronics)
  157. 157. 3D welding seam as design element
  158. 158. no static clamping device</li></li></ul><li>14.01.2010<br />Page 35<br /><ul><li>Basics
  159. 159. Concepts
  160. 160. Examples</li></ul>Industrial netting<br />Requirement:welding of 3D, large-area or endless components<br /> flexible like contour welding<br />Method: spot optic combined with a dynamic clamping device <br />Globo welding<br />Material:<br />PA transparent / <br />PA black<br />Specifications:<br /><ul><li> high speed
  161. 161. no static clamping device</li></li></ul><li>14.01.2010<br />Page 36<br /><ul><li>Basics
  162. 162. Concepts
  163. 163. Examples</li></ul>Gas-Analyzing-System<br />Requirement:welding of 3D, large-area or endless components<br /> flexible like contour welding<br />Method: spot optic combined with a dynamic clamping device <br />Globo welding<br />Material:<br />ABS nature / <br />ABS black<br />Photo: Leister, by courtesy of comp. Testo (Germany)<br />Specifications:<br /><ul><li> overall-size: 250 x 200 x 15 mm
  164. 164. welding seam length: approx. 3000 mm
  165. 165. welded on both sides
  166. 166. preservation of channel profile</li></li></ul><li>14.01.2010<br />Page 37<br /><ul><li>Basics
  167. 167. Concepts
  168. 168. Examples</li></ul>Tank adaptor<br />Requirement: welding of rotationally symmetrical components without relative motion<br />Method: two-mirror-scanner and conical mirror<br />Radial welding<br />Material:<br />PA nature (cap)<br />PA black / PE nature (ring)<br />Specifications:<br /><ul><li> permeability
  169. 169. high mechanical strength</li></ul>Photo: Leister, by courtesy of com. Rasmussen, Maintal (Germany)<br />
  170. 170. 14.01.2010<br />Page 38<br /><ul><li>Basics
  171. 171. Concepts
  172. 172. Examples</li></ul>Demo (Messe: K 2004)<br />Requirement: welding of rotationally symmetrical components without relative motion<br />Method: two-mirror-scanner and conical mirror<br />Radial welding<br />Material:<br />PMMA natural / ABS grey<br />
  173. 173. 14.01.2010<br />Page 39<br /><ul><li>Basics
  174. 174. Concepts
  175. 175. Examples
  176. 176. Laser Systems</li></ul>Laser Welding Machines<br />NOVOLAS Basic<br />NOVOLAS WS<br />NOVOLAS micro<br />
  177. 177. 14.01.2010<br />Page 40<br />LASERSYSTEMS<br />Distributed in the UK by:<br />For further details contact:Paul Anderson+44 1435 864239leister@horizoninstruments.co.uk<br />Adapted from a presentation by:Dipl. Ing. Oliver Hinz<br />Product Manager<br />
  1. A particular slide catching your eye?

    Clipping is a handy way to collect important slides you want to go back to later.

×