Laser Transmission Welding of Polymers
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Laser Transmission Welding of Polymers

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

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

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Laser Transmission Welding of Polymers Laser Transmission Welding of Polymers Presentation Transcript

  • 14.01.2010
    Page 1
    PLASTIC WELDINGwithLASER SYSTEMS
    Distributed in the UK by:
  • 14.01.2010
    Page 2
    • Basics
    • Concepts
    • Examples
    Material requirements:
    • Top part laser-transparent material
    • Bottom part laser-absorbent material
    • Compatible materials
    • Melt Temp
    • Chemical Compatibility
    Transparent joining part
    Welding seam
    Lasers radiation
    vs.
    Process requirements:
    • Good thermal contact
    • Pressure
    • Clear access for laser
    Melt zone
    Absorbing joining part
    Laser Transmission Welding
  • 14.01.2010
    Page 3
    • Basics
    • Concepts
    • Examples
    Transparent joining part
    Welding seam
    Lasers radiation
    vs.
    Melt zone
    Absorbing joining part
    Laser Transmission Welding
  • 14.01.2010
    Page 4
    • Basics
    • Concepts
    • Examples
    IR
    IR
    d
    d
    IL
    IL
    IT
    dopt  d
    dopt >> d
    Absorption Characteristics
    Joining part:
    • “no” absorption dopt >> d  “no“ heating
    • volume-absorption dopt  d  heating across the whole thickness
    • surface-absorption dopt << d  near surface heating
    d
    IR
    IT
    IL
    dopt&lt;&lt; d
  • 14.01.2010
    Page 5
    • Basics
    • Concepts
    • Examples
    Laser
    Lasers in material processing
    HPDL*= high power diode laser
    properties of HPDL (diode laser)  • high efficiency
    •compact
    • low-maintenance/ high life time
    • low beam intensity
  • 14.01.2010
    Page 6
    • Basics
    • Concepts
    • Examples
    Weldable Materials
    • Thermoplastics ~ Amorphous and semi-crystalline polymers (like - like) materials welded successfully:
    • 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….
    • Thermoplastic Elastomers:
    • Thermoplastic Elastomer to Thermoplastic Elastomer
    • Thermoplastic Elastomer to non-elastomeric thermoplastics
    • Colour-combination possibilities:
    • Black - Black (special non-carbon colouring in one part)
    • Transparent – transparent (with addition of “clearweld”)
    • Other colours with special pigments
  • 14.01.2010
    Page 7
    • Basics
    • Concepts
    • Examples
    Welding Seam Design
  • 14.01.2010
    Page 8
    • Basics
    • Concepts
    • Examples
    Design Considerations
    Weldability of Material
    Material A and B are based on the same material (PC with PC / ABS with ABS....)
    Material A and B are made of different but compatible materials (PMMA with ABS, PC with PBT.............)
    Optical properties of the Material is Suitable for Laser Transmission Welding?
    Material A - transparent to laser radiation (e.g. clear material)
    Material B - absorbs the laser radiation (e.g. Contains 1% Carbon Black)
    Dimensions and shape of part and the welding seam are designed laser compatible?
    Accessibility for laser, planarity, possibility to apply pressure?
  • 14.01.2010
    Page 9
    • Basics
    • Concepts
    • Examples
    Mask welding
    Globo welding
    Welding Concepts
    Contour welding
    Simultaneous welding
    Quasi-simultaneous welding
    Radial welding
  • 14.01.2010
    Page 10
    • Basics
    • Concepts
    • Examples
    Contour Welding
    Contour welding
    • Spot laser guided by X-Y Axis
    • Highly Flexible
    • Simple Weld Design
    • Ideal for Quick Changeover
  • 14.01.2010
    Page 11
    • Basics
    • Concepts
    • Examples
    Simultaneous Welding
    • Optic element used to form laser
    • One shot welding of weld seam
    • No relative movement
    • Short process times
  • 14.01.2010
    Page 12
    • Basics
    • Concepts
    • Examples
    Quasi-Simultaneous Welding
    Quasi-simultaneous welding
    • Mirrors guide laser over weld seam
    • High flexibility
    • Welding with displacement
    • Gap bridging possible
  • 14.01.2010
    Page 13
    • Basics
    • Concepts
    • Examples
    Mask welding
    Mask Welding
    • Line Beam Laser and Mask
    • Large areas and fine lines
    • Complex contours and shapes
    • Protection of sensitive parts
  • 14.01.2010
    Page 14
    • Basics
    • Concepts
    • Examples
    Radial Welding
    • Radial radiation
    • No rotation of part
    • Short process times
    • Ideal for welding axially symmetric / Cylindrical
    • Push fit
    Radial welding
  • 14.01.2010
    Page 15
    • Basics
    • Concepts
    • Examples
    Globo welding
    Globo Welding
    • Dynamic Clamping
    • Simple Joining Geometry
    • Continuous Welding
    • Ideal for 3-dimensional and large parts
  • 14.01.2010
    Page 16
    • Basics
    • Concepts
    • Examples
    Contour welding
    Laser Transmission Welding
    Advantages of laser welding:
    • high precision
    • high strength
    • minimal mechanical stress
    • minimal thermal stress
    • no damage to electronic components
    • simple joining geometry
    • low tool wear
    • emission free
    • particulate free
    • no consumables (adhesive/fasteners)
    • joining of elastomers
    Globo welding
  • 14.01.2010
    Page 17
    • Basics
    • Concepts
    • Examples
    Origin: IMM
    Origin: ILT
    Origin: Eppendorf
    Origin: Eppendorf
    Mask welding
    Requirement: welding of small structures (micro fluidics) changeable width of welding seam
    Method: line-beam-laser and structured mask
    Mask welding
  • 14.01.2010
    Page 18
    • Basics
    • Concepts
    • Examples
    Contour welding
    Requirement:extremely flexible with excellent welding results
    Method:spot optic with moving axis
    Contour welding
  • 14.01.2010
    Page 19
    • Basics
    • Concepts
    • Examples
    Simultaneous welding
    Requirement:short-time process
    no relative motion mass production
    Method:laser beam is formed and guided by static optical elements
    Simultaneous welding
  • 14.01.2010
    Page 20
    • Basics
    • Concepts
    • Examples
    Quasi-simultaneous welding
    Requirement:no relative motion
    flexible like contour welding
    short time process like simultaneous welding
    Method:two-mirror-scanner
    Quasi-simultaneous welding
  • 14.01.2010
    Page 21
    • Basics
    • Concepts
    • Examples
    Globo welding
    Requirement:welding of 3D components, large areas or continuous-feed applications
    flexible like contour welding
    Method: spot optic combined with a dynamic clamping device
    Globo welding
    Quelle: ILT
  • 14.01.2010
    Page 22
    • Basics
    • Concepts
    • Examples
    Radial welding
    Requirement: welding of rotationally symmetrical components without relative motion
    Method: special optics and conical mirror
    Radial welding
    Photo: Leister, by courtesy of comp. Rasmussen, Maintal (Germany)
  • 14.01.2010
    Page 23
    • Basics
    • Concepts
    • Examples
    Micro pump
    Requirement: welding of small structures (micro fluidics) changeable width of welding seam
    Method: line-beam-laser and structured mask
    Mask welding
    Material:
    PC transparent /
    PC black
    Specifications:
    • permeability
    • preservation of canal profile
    • canal width down to 100 µm
    • short processing time (3 seconds)
    Photo: Leister, by courtesy of IMM, Mainz (D)
  • 14.01.2010
    Page 24
    • Basics
    • Concepts
    • Examples
    Mixer-component
    Requirement: welding of small structures (micro fluidics) changeable width of welding seam
    Method: line-beam-laser and structured mask
    Mask welding
    Material:
    PC nature /
    PC black
    (both structured)
    Specifications:
    • permeability
    • preservation of 3D channel profile
    • channel width down to 130 µm,
    • overall size 35 x 40 x 4 mm
    Origin: FhG-ICT
  • 14.01.2010
    Page 25
    • Basics
    • Concepts
    • Examples
    Gas-Analyzing-System
    Requirement:extremely flexible with excellent welding results
    Method:spot optic and axis system
    Contour welding
    Material:
    ABS natural /
    ABS black
    Specifications:
    • overall-size: 250x200x15 mm3
    • welding seam length: approx. 5000 mm
    • welded on both sides
    • preservation of channel profile
    Photo: Leister, by courtesy of comp. Testo (Germany)
  • 14.01.2010
    Page 26
    • Basics
    • Concepts
    • Examples
    Electronic Key
    Requirement:extremely flexible with excellent welding results
    Method:spot optic and axis system
    Contour welding
    Material:
    PA laser transparent black
    PA black
    Specifications:
    • impermeability
    • no damage to electronics
    • no melting bulge
    Photo: FHG - ILT
  • 14.01.2010
    Page 27
    • Basics
    • Concepts
    • Examples
    Compensation tank
    Requirement:extremely flexible with excellent welding results
    Method:spot optic and axis system
    Contour welding
    Material:
    PA 6 GF 30 nature
    PA 6 GF 30 black
    Specifications:
    • permeability
    • no contamination (particles)
    Photo: FHG - ILT
  • 14.01.2010
    Page 28
    • Basics
    • Concepts
    • Examples
    Electronic housing
    Requirement:extremely flexible with excellent welding results
    Method:spot optic and axis system
    Contour welding
    Material:
    PC laser transparent black
    PBT GF 30 black
    Specifications:
    • permeability
    • No damage to electronic components
    Photo: Leister, by courtesy of comp. Elektra, Schalkau (Germany)
  • 14.01.2010
    Page 29
    • Basics
    • Concepts
    • Examples
    Optical Sensor
    Requirement:short-time process
    no relative motion mass production
    Method:laser beam formed and guided by optical elements
    Simultaneous welding
    Material:
    PMMA transparent red
    PC black
    Specifications:
    • no optical distortion
    • no contamination (particles)
    • pressure (> 12 bar)
    • permeability
  • 14.01.2010
    Page 30
    • Basics
    • Concepts
    • Examples
    Housing Flow-Sensor
    Requirement:short-time process
    no relative motion mass production
    Method:laser beam formed and guided by optical elements
    Simultaneous welding
    Material:
    PMMA natural
    ABS grey
    Specifications:
    • no contamination (particles)
    • preservation of electronics and chips
  • 14.01.2010
    Page 31
    • Basics
    • Concepts
    • Examples
    Display window
    Requirement:short-time process
    no relative motion mass production
    Method:laser beam formed and guided by optical elements
    Simultaneous welding
    Material:
    PC nature
    PC black
    Specifications:
    • permeability
    • no optical distortion
  • 14.01.2010
    Page 32
    • Basics
    • Concepts
    • Examples
    Demo (Fair: K 2004)
    Requirement:short-time process
    no relative motion mass production
    Method:laser beam formed and guided by optical elements
    Simultaneous welding
    Material:
    PC nature / PC black
  • 14.01.2010
    Page 33
    • Basics
    • Concepts
    • Examples
    Camshaft sensor
    Requirement: welding of rotationally symmetrical components without relative motion
    Method: two-mirror-scanner and conical mirror
    Radial welding
    Material:
    PA 66 GF 30 laser transparent black
    PA 66 GF 30 black
    Specifications:
    • permeability
    • no contamination (particles)
    • protection of electronic parts / sensors
    Photo: Leister, by courtesy of comp. Delphi Automotive, Luxemburg
  • 14.01.2010
    Page 34
    • Basics
    • Concepts
    • Examples
    Automotive lighting
    Requirement:welding of 3D, large-area or endless components
    flexible like contour welding
    Method: spot optic combined with a dynamic clamping device
    Globo welding
    Material:
    PMMA transparent /
    ABS black
    Specifications:
    • no thermal and mechanical stress (Electronics)
    • 3D welding seam as design element
    • no static clamping device
  • 14.01.2010
    Page 35
    • Basics
    • Concepts
    • Examples
    Industrial netting
    Requirement:welding of 3D, large-area or endless components
    flexible like contour welding
    Method: spot optic combined with a dynamic clamping device
    Globo welding
    Material:
    PA transparent /
    PA black
    Specifications:
    • high speed
    • no static clamping device
  • 14.01.2010
    Page 36
    • Basics
    • Concepts
    • Examples
    Gas-Analyzing-System
    Requirement:welding of 3D, large-area or endless components
    flexible like contour welding
    Method: spot optic combined with a dynamic clamping device
    Globo welding
    Material:
    ABS nature /
    ABS black
    Photo: Leister, by courtesy of comp. Testo (Germany)
    Specifications:
    • overall-size: 250 x 200 x 15 mm
    • welding seam length: approx. 3000 mm
    • welded on both sides
    • preservation of channel profile
  • 14.01.2010
    Page 37
    • Basics
    • Concepts
    • Examples
    Tank adaptor
    Requirement: welding of rotationally symmetrical components without relative motion
    Method: two-mirror-scanner and conical mirror
    Radial welding
    Material:
    PA nature (cap)
    PA black / PE nature (ring)
    Specifications:
    • permeability
    • high mechanical strength
    Photo: Leister, by courtesy of com. Rasmussen, Maintal (Germany)
  • 14.01.2010
    Page 38
    • Basics
    • Concepts
    • Examples
    Demo (Messe: K 2004)
    Requirement: welding of rotationally symmetrical components without relative motion
    Method: two-mirror-scanner and conical mirror
    Radial welding
    Material:
    PMMA natural / ABS grey
  • 14.01.2010
    Page 39
    • Basics
    • Concepts
    • Examples
    • Laser Systems
    Laser Welding Machines
    NOVOLAS Basic
    NOVOLAS WS
    NOVOLAS micro
  • 14.01.2010
    Page 40
    LASERSYSTEMS
    Distributed in the UK by:
    For further details contact:Paul Anderson+44 1435 864239leister@horizoninstruments.co.uk
    Adapted from a presentation by:Dipl. Ing. Oliver Hinz
    Product Manager