Objectif
Extensive welding investigations have been performed with a considerable number of materials, including both hard polymers and elastomers, and with the help of various types of laser-equipment. As a result, the above-mentioned objectives have, broadly, been attained.
Various demonstrator products have been realised for:
- components for the automotive industry;
- electronic components or encapsulations of these;
- optical and electro-optical products, such as components for information storage;
- biomedical products;
- double-walled window-systems;
- housings of electronic products. Furthermore, samples of new materials with improved properties for laser-welding have been made.
As to equipment, diode-laser systems for polymer welding have been developed, including a camera for positioning and an integrated pyrometer for process monitoring and real-time feedback control of the welding temperature.
An overall assessment of laser welding, including materials, equipment, process conditions and economic aspects has been performed, and indicates that polymer welding by means of diode-lasers looks attractive from both a technical and an economical point of view, and is expected to gain a significant position beside other joining processes.
Objectives and content
Permanent and often hermetic sealing of plastic housings
is an important problem in a wide range of industrial
production in Europe. Examples are: automotive modules
such as lighting units, encapsulations of electronic and
electric components such as miniature relays, housings of
personal care products such as electric shavers,
specialised micro-products such as microfluidic devices,
and plastic double-walled windows.
These sectors strive for products with higher quality,
improved appearance, complex 3-D curved design contours
(high-design products), made at lower costs by means of
reliable processes. In this respect, joining technology
plays a crucial role as it is needed for virtually all
products and has a strong impact on the above mentioned
factors. Conventional sealing technology such as
adhesive bonding, ultrasonic welding and induction
welding fall short in important respects. The
shortcomings are inherent to these technologies.
Therefore, there is a need for a completely new joining
technology that can fulfil all requirements. In addition,
flexibility is a key factor, as well as high position
accuracy in case of miniature products.
High-power laser-diode welding of polymers has the
potential to become such a technology. High-power, nearinfra-red diode-lasers are just beginning to emerge and
promise to become a laser-type that is cost-effective and
has a beam quality that is ideally suited for welding of
polymers. The proposed project concerns the development
of this welding technique and is targeted at the
following objectives:
reliable process producing high-quality joints.
hermetic closure.
high position accuracy: better than 1 mm in the
height-direction for miniature products.
no exterior (appearance) or interior (functionality)
damage to product; no burrs.
fast process: cycle-times < 2 s for miniature products.
high flexibility: rapid switching to another product
type.
The proposed project encompasses three main lines of
research:
Process development: both rather basic and application oriented.
Materials development; materials are needed with the
right absorbing properties for the (infra-red) laser
radiation.
Development of high-power laser-diode systems suitable
for polymer welding.
The Consortium brings together all specialists in the
field from different countries. Only by close
cooperation of international partners it is possible to
develop this strategic, innovative and versatile joining
process. The Consortium comprises as end-users: Philips
(NL), Siemens (DE), Fiat (IT), microParts (DE) and
Thermoform (DK), which cover a broad range of industrial
sectors, allowing an evaluation of the technology in all
its important aspects. Materials are developed by
manufacturers DSM (NL) as regards plastics and Zeneca
(GB) as regards dyes tailored to the required infra-red
absorbent / transmittive properties, while the University
of Leuven (BE) will investigate basic material
properties. Rofin Sinar (DE) will take part as developer
and manufacturer of laser systems. ILT (DE) will do basic
research, both on process and lasersystems.
Champ scientifique (EuroSciVoc)
CORDIS classe les projets avec EuroSciVoc, une taxonomie multilingue des domaines scientifiques, grâce à un processus semi-automatique basé sur des techniques TLN. Voir: Le vocabulaire scientifique européen.
CORDIS classe les projets avec EuroSciVoc, une taxonomie multilingue des domaines scientifiques, grâce à un processus semi-automatique basé sur des techniques TLN. Voir: Le vocabulaire scientifique européen.
- ingénierie et technologie génie électrique, génie électronique, génie de l’information ingénierie électronique capteurs capteurs optiques
- sciences naturelles sciences chimiques science des polymères
- ingénierie et technologie génie mécanique génie automobile ingénierie automobile
- sciences naturelles sciences physiques optique physique des lasers
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Pays-Bas
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