Ch.

11 Plastic Welding & Adhesive bonding

Polymer = Poly (Numerous) + Mer (Chemical Unit)

= Numerous Repeating Chemical Unit

Bond status:
Covalent bond (Within the chain) + Secondary bond (Between chains)

Plastics are classified into Thermoplastic, Thermoset and Rubber depending on cross-link.

Since thermoplastic can be remelt, it is further classified into Amorphous and Semi-
Crystalline depending on the cooling rate.

Table 11.1 Comparison of amorphous and semi-crystalline

amorphous semi-crystalline
generally flexible generally rigid
more likely be transparent more compact and ordered structure
at T>Tg, viscosity changes gradually more likely be opaque
T>Tg for welding higher working and processing temp.
more solvent-resistance
T>Tm for welding
 Plastic welding methods

For thermoplastic, you can use various methods for welding.

For thermoset, you can use only adhesive bonding and mechanical fastening methods.

Most plastic welding process is melting the thermoplastics using various heat sources.

Table 11.2 Polymer bonding methods

Plastic welding method Process

Hot gas welding
Extrusion welding
1. External heating method Hot tool welding
Implant resistance welding
Implant induction welding
Ultrasonic welding
2. Internal heating method Vibration welding
Spin welding
Radio frequency welding
Microwave welding
3. Electromagnetic heating method
Infrared welding
Laser welding
Thermoplastic adhesives
4. Adhesive bonding
Thermoset adhesives
 Hot plate (tool) welding

Laser welding
- Through-transmission welding
- Selective welding with Mask
 Adhesive bonding mechanism

There are many theories about adhesive bonding mechanism

1. Adsorption and Chemisorption

2. Mechanical interlocking
3. Electrostatic force
4. Diffusion (Thermoplastic only)

Adsorption

Secondary bonds

Chemisorption

It is a rare case.
Highest bond strength
with chemical bonds
 Adhesive bonding mechanism

Mechanical interlocking
(It is useful for metal bonding)

Diffusion

It is applied for thermoplastic

only.

Electrostatic
 Features of adhesive bonding

Factors influencing adhesion

• Wetting
• Surface treatment (e.g., flame/plasma or priming/coating)
• Materials
• Joint design (bond area, external force, etc.)

Pros & Cons of adhesive bonding

• Wide application range

• Low bonding temperature
• Various adhesives (thermoplastic, thermoset)

• Not hermetic sealing

• Low bond strength (Secondary bond)
• Properties vary depending on temp. and time

There are many theories about adhesive bonding

Please read the Appendix…