Internal structure of Chongqing plastic parts is clean and free of debris.
Release Date:
2022-08-10
Compared with conventional ultrasonic welding, plastic laser welding offers the following distinct advantages:
1. Clean welding. Physical contact with the workpieces to be welded is avoided, chemical changes in thermosetting plastics are prevented, and epoxy resin dissolution is minimal. Laser-welded plastic components from Chongqing exhibit a clean internal structure free of debris, thereby resolving the issue of ultrasonic-welded debris clogging oil filters and other filtration products. This process is also well-suited for industries that demand high levels of safety and hygiene, such as medical and food manufacturing. In the medical-device sector, it is primarily used in the production and processing of injection systems, diagnostic electronic devices, and related products.
2. Welding offers excellent cost-effectiveness. It delivers high precision, robustness, and airtight sealing while preventing water ingress, thereby overcoming the challenges associated with ultrasonic welding of high-precision plastic components—namely, component damage and reduced stability.
3. Low residual welding stress and high weld strength. Compared with conventional fusion welding, this method significantly reduces both residual stress and vibration-induced stress, making the welded joints less prone to cracking in the mid- and later stages of service and substantially extending the service life of components.
4. Broad adaptability in appearance design. The laser beam’s parameters are precisely controllable, enabling precise regulation of the heat-affected zone and the dimensions of the joint area, with high degrees of freedom and excellent process coordination. It excels at welding components with complex geometries, capable of performing both two-dimensional and even three-dimensional welding, thereby laying a solid foundation for the diversified and customized production of plastic parts in Chongqing.
5. Elegant and aesthetically pleasing appearance. Utilizing laser welding of plastics through the weld joint, the surface is clean and smooth, with no visible weld marks, achieving both superior strength and a flawless aesthetic finish.
Basic Principles of Plastic Laser Welding
In laser welding of thermosetting plastics, the process is sometimes referred to as “laser scattering welding” or “scattering infrared welding (TTlr).” The principle involves using a bilayer weld material in which one layer is transparent to the laser beam and the other is absorptive. The laser beam passes through the transparent layer and is converted into heat at the surface of the absorptive layer. During welding, as the two layers are pressed together, heat is conducted from the absorptive layer into the transparent layer, causing both materials to melt and bond simultaneously. At the same time, thermal deformation and thermal expansion of the materials generate internal stresses; these internal stresses, combined with external clamping pressure, ensure a strong and reliable joint between the two parts.
Common plastic welding methods include ultrasonic welding, vibration friction welding, and heated-plate welding. Each method is suited to weldments of different sizes and shapes; the relative advantages and disadvantages are illustrated in the figure below.
Plastic laser welding and the forgeability of raw materials
In plastic welding, materials made from the same raw material generally exhibit good weldability; however, even different materials can possess a certain degree of weldability. The color and glass-fiber content of the plastic are critical factors determining the success of laser welding. The difficulty level of welding various materials ranges from easy to difficult.
For raw materials with insufficient light absorbance, it is common practice to enhance their performance by adding an adsorbent. For dark-brown raw materials, welding can be achieved by exploiting the difference in transmittance between two layers of material; the greater the difference in transmittance, the more ideal the welding result.
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