Gentex Corp. offers European plastics fabricators new laser welding technology
Clearweld® process uses near-IR-absorbing materials to produce instant, colorless welds
5/9/2003
Gentex Corporation now offers its patented Clearweld method for laser welding clear, colored and opaque thermoplastics in Europe. The company now provide European plastics fabricators with a line of products for implementing the Clearweld process, which produces welds without particulates, flash, adhesives or adding unwanted color.
Gentex is also in the process of negotiating a variety of strategic partnerships to accelerate adoption of the technology in Europe. Gareth McGrath, formerly head of the Polymer Technology Group at TWI, a U.K.-based industrial research and development organization that specializes in material joining, recently joined the company as European business development manager based in Cambridge, England.
The Clearweld process uses Gentex’s near-infrared-absorbing materials to convert laser energy into heat. A thin layer of these materials applied at the interface of two pieces of plastic to be joined absorbs the light, acting as a focal point for the laser.
Localized heating of the substrates occurs at the joint interface, producing an instant weld with no material deformation and making it ideal for applications ranging from micro-fluidics to electronic packaging components.
Besides clean, optically clear joints, the Clearweld process yields weld strengths that are comparable or superior to other joining techniques, such as hot plate, ultrasonic and solvent bonding. Moreover, it accommodates preassembly and high weld speeds, permits 3-D contour joint lines and facilitates rapid changeover to different products. In addition, process parameters can be controlled precisely, and low heat input reduces the risk of thermal distortion or damage.
The material systems are formulated to match substrates and optimize absorption of diode and Nd YAG lasers in the 940nm to 1,064nm wavelength range with other wavelengths to be addressed in the future. The process is dependent upon accurate and repeatable application of the material at the localized joint interface. Initially Gentex will focus on formulating these material systems for application via ink jet printing and liquid dispensing. The Clearweld process is patented in Europe with additional patents pending.
Clearweld was developed jointly by Gentex and TWI with Gentex retaining the exclusive rights to commercialize the process worldwide.
About Gentex
Established in 1892, Gentex is a privately owned corporation with four operating units: helmet systems, performance materials, respiratory products and electro-acoustic products. One of the company’s major markets is defense, encompassing both U.S. armed forces and the military units of other nations. The company is a world leader in both military and commercial markets with extensive research and development capabilities.