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© µ-Joining µC 121206
121203 LCS




                                             Micro - Joining,
                                the Adhesive Bonding Approach.




                                                             Themadag Mikrocentrum
                                                          Eindhoven – 6 december 2012




LCS Belgium bvba, Consultancy in Adhesive Bonding Technology
                                                    www.lcs-adhesivebonding.com
 Where it’s all about …
• Introduction … always with examples
• Bonding as alternative for …
• What is bonding ? The theory …
• Surface Treatment Methods
• External Influences
• Adhesive Types
• Design with Adhesives
• Examples including equipment and QC
• Conclusion

NASA – Spaceshuttle – Heatshield              vs     Medical Needle – PP to Inox

Bonding: an alternative for …
• Welding: – Electric Arc Welding, – Ultrasonic Welding, – Laser Welding
• Soldering
• Screws, Bolts & Nuts
• Clinch-nails & Rivets
• Folding, Pressing en Flowdrilling
• Clasp constructions & Springs
• Sewing, Stitching & Stapling

Advantages of Adhesives
• Easy & Fast: less rework
• Also for dissimilar materials – e.g. metal-plastic & thick-thin
• Higher Strength: uninterrupted joint – No or less weak points
• Improved Stress-distribution & -reduction – Higher fatiguestrength
• Sealing: corrosion prevention – Liquid- & gastight
• Damped Vibrations – less Noise S&R
• Light: weight reduction
• Esthetic: invisible
• Bonding also “Thin” & “Small” components
• Less componentsµ




LCS Adhesive Bonding bvba                                      Copyright ©              2012-06-07
Pseudo-disadvantages of Bonding
• It’s “Chemistry” ! It’s a mess !? = Operator dependent
• Environmental aspects: – Water based adhesives – Recycling of adhesive and cleaners
• Cleanliness of substrates
• Design flexibility: is manageable
• Speed: adhesive type dependent
• Dangers: exothermic reactions, H&S
• Difficult Disassembly: recycling
• Limited Strength & Temperature Resistance

Sticking as a Gecko – IFAM
• Subtle hairs with a molecular bond: van der Waals forces


                                          What’s “Bonding” ? Definition

                                          Joining of
                                       two substrates
                                        by means of a
                                        third medium
                                       = the adhesive



                                                Adhesion vs Cohesion

                         LCS 100218                          Copyright LCS   ®          18




What’s “Bonding” ? Mechanisms (cfr Wikipedia)
• Vanderwaals: – Glassplates experiment
• Chemical: – Si primer
• Mechanical: – Surface roughness

But what’s really on the ‘Surface’ ?!
Surface condition of substrates !!!

Why Surface Treatment ?
• Strength: adhesion - cohesion ( rupture )
• Wetting ( > 40 Dyne/cm)
• ‘Contact Angle’ measurement
• Watertest

Pretreatment of substrates
• Degreasing: cloth, vapour, ultrasonic
• Grinding: roughen = > surface
• Blasting: grit-, ice- . NON-recirculating !
• Primers: silanes – thickness = µm
• Chemical etch: bv Aluminium
• Flame & Corona: foil & sheet
• Plasma: vacuum & atmospheric – CA!
• Laser: surface structure change

Failure Types
• Cohesive failure: in the adhesive
• Adhesive failure: on the surface of at least one of the substrates
• Material Failure: one of both substrates
• Mixed Failure: a combination of the above




LCS Adhesive Bonding bvba                            Copyright ©                             2012-06-07
Failure Types Medical needles
• Cohesion failure: lack of cure
• Material failure: plasma treated + fully cured

Surface Treatment with Atmospheric Plasma – Video
External Influences
• Time: aging – degradation in function of time
• Temperature: -change en thermoshock – under the hood: -55° tot +125°
                                                                  C               C
• Vibrations & Shock: noise - S&R
• Chemical: salt + humidity = corrosion
• Radiation: X-ray, α-, β-, γ-radiation – Radioactive – Light: UV degradation – color permanency
• Medical: USP Class VI – ISO 10993 - sterilisation, biocompatibility, citotoxicity
Adhesive Types - Graph
• Epoxy: highest performance, chemical resistant
• Polyurethane: humidty sensitive, cheap
• Silicone: flexible, price ↑, Mix-Ratio, Visc ≠ f(T)
• Phenolics: high temperature applications
• UV & light- curing: fast, price ↑, light sensitive
• Acrylates: highest strength, smell, initiators
• Cyanoacrylates: moisture cure
• Anaerobics: thread lock – metal+ & air cut off
• Hybrids : EP/Si, PU/EP, UV + moisture or T …
• Exotics: polybutadiene, MS-polymer, PSA, …
• Hotmelts: cheap, reactive types, performance
• Tapes: single and double sided
• Ceramic : HT – Waterglass

Ink Cartridges
Gas Filtration
Heat Exchanger
Solvent Based Adhesives
• Medical disposables: – Stress Cracking
• Urgency repair of panty’s: – Acetone based nail remover
• Solvent alternatives
Adhesive Types – UV & LIGHT Curing
• Medical needles
• Glass & plexiglass structures
• CD – DVD lens focus mechanism
• ‘Carglass’ repair
• Jewelry
     – Cristal’ clear • Refractive index • Non-yellowing • Fast curing • No oxygen inhibition – not tacky • Strong

Health & Safety – H&S - That’s why there are Safety Measures …
Design = alternative thinking
• Tensile - Trekbelasting
• Shear – Afschuiving L&R – Best for Bonding Applications
• Cleavage - Splijtbelasting
• Peel - Afpelbelasting

Examples (cont’d)
• Tea bags
• Medical Needles en Catheters
• Curing of Adhesives - Timing
• Ra-ra-ra what’s this ?
• Glucose Test
• Blood Tubes
• Detector in Toothbrush
• Modelbouw
• Balloon Catheder
• Pacemakers & Hearing Aids
• Surgical Glue & Dental Surgery
• Nageltrends
• Scanner Sensors
• CA Rubber Bonding
• CD/DVD Laser
• Motor Control



LCS Adhesive Bonding bvba                               Copyright ©                                2012-06-07
• RFID – Identification Systems
• SMD in Electronics
• Watch Mechanism with Chip
• Stacking Potentiometers
• Piezo Diesel Injection
• Piezoelectric Evaporation Device
• Biological Pest Control
• Shaver Blade Cover
• Dosing Equipment – Volumetric – XYZ – 2K
• Nano dispensing equipment - 1 mm - 10 nl
• Chip Packaging in Micro-Electronics
• Fiber-Optics

Quality Control with Vision System
• A: non Fluo • B: non Fluo • C: OK • D: Defect

A few Trends
• Multiple functionalities: Vibration dampening - S&R

• More composites and ‘all-in’ adhesives
• Increasing Price pressure ↑ : Lopez effect - raw materials & energy price increases
• Nanotechnology in adhesives
• It all happens on the surface, less in the adhesive
• Selfhealing Adhesives
• More automation with adhesives
• More ‘Bonding’ for your new Application

Conclusion
The only chance realising bonding projects successfully, is that the
“Triumvirate” of
             – the customer with his project
             – the glue manufacturer with the adhesive
             – the machine manufacturers with their equipment
is working intensively and expertly together, from the design phase on and
on all aspects of the application.
Success Guaranteed !

Thanks for your attention, and we welcome you in ’The Adhesive’s World’
LCS – Your partner in Adhesive Bonding
LCS Adhesive Bonding bvba Independent Consultancy in Adhesive Bonding Technology
Ing. Jan A. LAMBRECHTS MSc.
Bergenstraat 84
B-3053 Haasrode – Leuven
+32-(0)16-38 90 45
+32-475-45 48 98
jan.lambrechts@consultant.com
www.lcs-adhesivebonding.com


121203 LCS © µ-joining µC 121206




LCS Adhesive Bonding bvba                                            Copyright ©        2012-06-07

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Jan Lambrechts - LCS Belgium

  • 1. © µ-Joining µC 121206 121203 LCS Micro - Joining, the Adhesive Bonding Approach. Themadag Mikrocentrum Eindhoven – 6 december 2012 LCS Belgium bvba, Consultancy in Adhesive Bonding Technology www.lcs-adhesivebonding.com Where it’s all about … • Introduction … always with examples • Bonding as alternative for … • What is bonding ? The theory … • Surface Treatment Methods • External Influences • Adhesive Types • Design with Adhesives • Examples including equipment and QC • Conclusion NASA – Spaceshuttle – Heatshield vs Medical Needle – PP to Inox Bonding: an alternative for … • Welding: – Electric Arc Welding, – Ultrasonic Welding, – Laser Welding • Soldering • Screws, Bolts & Nuts • Clinch-nails & Rivets • Folding, Pressing en Flowdrilling • Clasp constructions & Springs • Sewing, Stitching & Stapling Advantages of Adhesives • Easy & Fast: less rework • Also for dissimilar materials – e.g. metal-plastic & thick-thin • Higher Strength: uninterrupted joint – No or less weak points • Improved Stress-distribution & -reduction – Higher fatiguestrength • Sealing: corrosion prevention – Liquid- & gastight • Damped Vibrations – less Noise S&R • Light: weight reduction • Esthetic: invisible • Bonding also “Thin” & “Small” components • Less componentsµ LCS Adhesive Bonding bvba Copyright © 2012-06-07
  • 2. Pseudo-disadvantages of Bonding • It’s “Chemistry” ! It’s a mess !? = Operator dependent • Environmental aspects: – Water based adhesives – Recycling of adhesive and cleaners • Cleanliness of substrates • Design flexibility: is manageable • Speed: adhesive type dependent • Dangers: exothermic reactions, H&S • Difficult Disassembly: recycling • Limited Strength & Temperature Resistance Sticking as a Gecko – IFAM • Subtle hairs with a molecular bond: van der Waals forces What’s “Bonding” ? Definition Joining of two substrates by means of a third medium = the adhesive Adhesion vs Cohesion LCS 100218 Copyright LCS ® 18 What’s “Bonding” ? Mechanisms (cfr Wikipedia) • Vanderwaals: – Glassplates experiment • Chemical: – Si primer • Mechanical: – Surface roughness But what’s really on the ‘Surface’ ?! Surface condition of substrates !!! Why Surface Treatment ? • Strength: adhesion - cohesion ( rupture ) • Wetting ( > 40 Dyne/cm) • ‘Contact Angle’ measurement • Watertest Pretreatment of substrates • Degreasing: cloth, vapour, ultrasonic • Grinding: roughen = > surface • Blasting: grit-, ice- . NON-recirculating ! • Primers: silanes – thickness = µm • Chemical etch: bv Aluminium • Flame & Corona: foil & sheet • Plasma: vacuum & atmospheric – CA! • Laser: surface structure change Failure Types • Cohesive failure: in the adhesive • Adhesive failure: on the surface of at least one of the substrates • Material Failure: one of both substrates • Mixed Failure: a combination of the above LCS Adhesive Bonding bvba Copyright © 2012-06-07
  • 3. Failure Types Medical needles • Cohesion failure: lack of cure • Material failure: plasma treated + fully cured Surface Treatment with Atmospheric Plasma – Video External Influences • Time: aging – degradation in function of time • Temperature: -change en thermoshock – under the hood: -55° tot +125° C C • Vibrations & Shock: noise - S&R • Chemical: salt + humidity = corrosion • Radiation: X-ray, α-, β-, γ-radiation – Radioactive – Light: UV degradation – color permanency • Medical: USP Class VI – ISO 10993 - sterilisation, biocompatibility, citotoxicity Adhesive Types - Graph • Epoxy: highest performance, chemical resistant • Polyurethane: humidty sensitive, cheap • Silicone: flexible, price ↑, Mix-Ratio, Visc ≠ f(T) • Phenolics: high temperature applications • UV & light- curing: fast, price ↑, light sensitive • Acrylates: highest strength, smell, initiators • Cyanoacrylates: moisture cure • Anaerobics: thread lock – metal+ & air cut off • Hybrids : EP/Si, PU/EP, UV + moisture or T … • Exotics: polybutadiene, MS-polymer, PSA, … • Hotmelts: cheap, reactive types, performance • Tapes: single and double sided • Ceramic : HT – Waterglass Ink Cartridges Gas Filtration Heat Exchanger Solvent Based Adhesives • Medical disposables: – Stress Cracking • Urgency repair of panty’s: – Acetone based nail remover • Solvent alternatives Adhesive Types – UV & LIGHT Curing • Medical needles • Glass & plexiglass structures • CD – DVD lens focus mechanism • ‘Carglass’ repair • Jewelry – Cristal’ clear • Refractive index • Non-yellowing • Fast curing • No oxygen inhibition – not tacky • Strong Health & Safety – H&S - That’s why there are Safety Measures … Design = alternative thinking • Tensile - Trekbelasting • Shear – Afschuiving L&R – Best for Bonding Applications • Cleavage - Splijtbelasting • Peel - Afpelbelasting Examples (cont’d) • Tea bags • Medical Needles en Catheters • Curing of Adhesives - Timing • Ra-ra-ra what’s this ? • Glucose Test • Blood Tubes • Detector in Toothbrush • Modelbouw • Balloon Catheder • Pacemakers & Hearing Aids • Surgical Glue & Dental Surgery • Nageltrends • Scanner Sensors • CA Rubber Bonding • CD/DVD Laser • Motor Control LCS Adhesive Bonding bvba Copyright © 2012-06-07
  • 4. • RFID – Identification Systems • SMD in Electronics • Watch Mechanism with Chip • Stacking Potentiometers • Piezo Diesel Injection • Piezoelectric Evaporation Device • Biological Pest Control • Shaver Blade Cover • Dosing Equipment – Volumetric – XYZ – 2K • Nano dispensing equipment - 1 mm - 10 nl • Chip Packaging in Micro-Electronics • Fiber-Optics Quality Control with Vision System • A: non Fluo • B: non Fluo • C: OK • D: Defect A few Trends • Multiple functionalities: Vibration dampening - S&R • More composites and ‘all-in’ adhesives • Increasing Price pressure ↑ : Lopez effect - raw materials & energy price increases • Nanotechnology in adhesives • It all happens on the surface, less in the adhesive • Selfhealing Adhesives • More automation with adhesives • More ‘Bonding’ for your new Application Conclusion The only chance realising bonding projects successfully, is that the “Triumvirate” of – the customer with his project – the glue manufacturer with the adhesive – the machine manufacturers with their equipment is working intensively and expertly together, from the design phase on and on all aspects of the application. Success Guaranteed ! Thanks for your attention, and we welcome you in ’The Adhesive’s World’ LCS – Your partner in Adhesive Bonding LCS Adhesive Bonding bvba Independent Consultancy in Adhesive Bonding Technology Ing. Jan A. LAMBRECHTS MSc. Bergenstraat 84 B-3053 Haasrode – Leuven +32-(0)16-38 90 45 +32-475-45 48 98 jan.lambrechts@consultant.com www.lcs-adhesivebonding.com 121203 LCS © µ-joining µC 121206 LCS Adhesive Bonding bvba Copyright © 2012-06-07