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

1. 14.01.2010 Page 1 PLASTIC WELDINGwithLASER SYSTEMS Distributed in the UK by:

3. Concepts

5. Bottom part laser-absorbent material

6. Compatible materials

7. Melt Temp

9. Pressure

10. Clear access for laserMelt zone Absorbing joining part Laser Transmission Welding

12. Concepts

13. ExamplesTransparent joining part Welding seam Lasers radiation vs. Melt zone Absorbing joining part Laser Transmission Welding

15. Concepts

17. volume-absorption dopt  d  heating across the whole thickness

18. surface-absorption dopt << d  near surface heatingd IR IT IL dopt&lt;&lt; d

20. Concepts

21. ExamplesLaser 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

23. Concepts

25. ABS, COC, PA, PBT, PC, PE, PMMA, PP, PS, SAN, ...

26. Combinations of different but compatible thermoplastics include:

27. PMMA-ABS, ABS-PC, ABS-SAN, PMMA-PC….

28. Thermoplastic Elastomers:

29. Thermoplastic Elastomer to Thermoplastic Elastomer

30. Thermoplastic Elastomer to non-elastomeric thermoplastics

31. Colour-combination possibilities:

32. Black - Black (special non-carbon colouring in one part)

33. Transparent – transparent (with addition of “clearweld”)

35. Concepts

36. ExamplesWelding Seam Design

38. Concepts

39. ExamplesDesign 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?

41. Concepts

42. ExamplesMask welding Globo welding Welding Concepts Contour welding Simultaneous welding Quasi-simultaneous welding Radial welding

44. Concepts

46. Highly Flexible

47. Simple Weld Design

49. Concepts

51. One shot welding of weld seam

52. No relative movement

54. Concepts

56. High flexibility

57. Welding with displacement

59. Concepts

62. Concepts

64. No rotation of part

65. Short process times

66. Ideal for welding axially symmetric / Cylindrical

67. Push fitRadial welding

69. Concepts

71. Simple Joining Geometry

72. Continuous Welding

74. Concepts

76. high strength

77. minimal mechanical stress

78. minimal thermal stress

79. no damage to electronic components

80. simple joining geometry

81. low tool wear

82. emission free

83. particulate free

84. no consumables (adhesive/fasteners)

85. joining of elastomersGlobo welding

87. Concepts

88. ExamplesOrigin: 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

90. Concepts

91. ExamplesContour welding Requirement:extremely flexible with excellent welding results Method:spot optic with moving axis Contour welding

93. Concepts

94. ExamplesSimultaneous welding Requirement:short-time process no relative motion mass production Method:laser beam is formed and guided by static optical elements Simultaneous welding

96. Concepts

97. ExamplesQuasi-simultaneous welding Requirement:no relative motion flexible like contour welding short time process like simultaneous welding Method:two-mirror-scanner Quasi-simultaneous welding

99. Concepts

100. ExamplesGlobo 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

102. Concepts

103. ExamplesRadial 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)

105. Concepts

107. preservation of canal profile

108. canal width down to 100 µm

109. short processing time (3 seconds)Photo: Leister, by courtesy of IMM, Mainz (D)

111. Concepts

113. preservation of 3D channel profile

114. channel width down to 130 µm,

115. overall size 35 x 40 x 4 mmOrigin: FhG-ICT

117. Concepts

119. welding seam length: approx. 5000 mm

120. welded on both sides

121. preservation of channel profilePhoto: Leister, by courtesy of comp. Testo (Germany)

123. Concepts

125. no damage to electronics

126. no melting bulgePhoto: FHG - ILT

128. Concepts

130. no contamination (particles)Photo: FHG - ILT

132. Concepts

134. No damage to electronic componentsPhoto: Leister, by courtesy of comp. Elektra, Schalkau (Germany)

136. Concepts

138. no contamination (particles)

139. pressure (> 12 bar)

141. Concepts

144. Concepts

147. Concepts

148. 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

150. Concepts

152. no contamination (particles)

153. protection of electronic parts / sensorsPhoto: Leister, by courtesy of comp. Delphi Automotive, Luxemburg

155. Concepts

157. 3D welding seam as design element

159. Concepts

162. Concepts

164. welding seam length: approx. 3000 mm

165. welded on both sides

167. Concepts

169. high mechanical strengthPhoto: Leister, by courtesy of com. Rasmussen, Maintal (Germany)

171. Concepts

172. ExamplesDemo (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

174. Concepts

175. Examples

176. Laser SystemsLaser Welding Machines NOVOLAS Basic NOVOLAS WS NOVOLAS micro

177. 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