Applied products of semiconductor laser Applied products of semiconductor laser

Laser plastic welding | Applied products of semiconductor lasers

Laser plastic welding is the processing method of plastic, which generates heat energy at welding interface by laser light and melt plastic in a non-contact manner. This is attracting attention due to the dissemination of high power semiconductor laser. Typical welding methods are Laser Transmission Welding Method and Laser Penetration Welding Method (=Absorbance Control Welding (ACW®)). These methods allow high-speed, high-strength and highly-waterproof welding, and are used as new processing methods in the automotive and electronic industries.

Principle of laser plastic welding

Laser transmission welding

l_apl_pw1_en

  1. Laser-transmitting plastic is placed on laser-absorbing plastic. Pressure is applied so that the two plastic pieces are in tight contact with each other.
  2. Irradiate laser. Laser light passing through the laser-transmitting plastic is absorbed by the laser absorbing plastic and heat is generated there.
  3. The heat generated at the laser-absorbing plastic is conducted to the laser-transmitting plastic and the two plastics are fused.
  4. Once laser irradiation stopped, the plastics are welded in the process of cooling⇒solidification.

Transparent and transparent

l_apl_pw2_en

  1. A laser absorbent is inserted between laser-transmitting plastic. Pressure is applied so that they are in tight contact with each other.
  2. Irradiate laser. Laser light passing through the laser-transmitting plastic is absorbed by the laser absorbent and heat is generated there.
  3. The heat generated at the laser absorbent is conducted to the lower laser-transmitting plastic and the laser-transmitting plastic is fused.
  4. Once laser irradiation stopped, the plastics are welded in the process of cooling⇒solidification.

*Example of plastic welding not possible

If both plastic absorb laser light, heat generation occurs only at the surface where laser light is absorbed and the plastic are not welded.

 

l_apl_pw3_en

Examples of laser plastic welding

▲Transparent and transparent

▲Black and black

Advantages of laser plastic welding

Improvement of process efficiency

  • Reduction of number of required parts → No O-rings, no adhesives
  • Simplification of process → Welding and waterproof just by laser irradiation
  • High speed → High speed welding
  • Stable process → No wear parts, consumables
  • Easy for full automation → Cost reduction

Added higher value to product

  • High strength welding → Welding strength equal to base material's strength
  • Minimal internal effect → No vibration, Local heating
  • Better external appearance → Weld interface only

Comparison table with other methods

  Laser welding Ultrasonic welding Hot plate welding Vibration welding Adhesive
Welding strength・reliability ☆☆☆☆☆ ☆☆☆☆☆ ☆☆☆☆☆ ☆☆☆☆☆ ☆☆☆
Internal effect ☆☆☆☆☆ ☆☆☆ ☆☆☆
High-mix low-volume production  ☆☆☆☆☆ ☆☆☆
Design freedom ☆☆☆☆ ☆☆☆ ☆☆☆ ☆☆☆☆
Productivity ☆☆☆☆☆ ☆☆☆☆☆ ☆☆☆ ☆☆☆☆☆ ☆☆☆
Stability ☆☆☆☆☆ ☆☆☆ ☆☆☆☆ ☆☆☆ ☆☆☆

Movie examples

Laser transmission welding

  • Even renewable resource materials (bioplastic) can be welded
  • Minimal environmental load (low electrical power consumption, no solvents) welding method

*Sample courtesy: DuPont  (renewable resource material Sorona®)

  • Pastel color material can be welded
  • Easy to match colors by applying a laser absorber

*Sample courtesy: Orient Chemical Industries Co., Ltd.

Laser absorbance control welding

  • Allows butt welding
  • Welding method with high margin for gap
  • Same materials welding is possible, which leads to reduction of mold costs

*Sample courtesy: Asahi-Kasei Corporation

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