Hybrid joining, welding and adhesive bonding of thermoplastics

Purpose and goal

The goal of the project was to develop a methodology and technology for joining vacuum-formed and injection-molded articles. The aim was to be able to increase the knowledge and understanding of ultrasonic welding of vacuum formed articles. This to be an attractive joining method. The project intended to reach TRL 5, but reached TRL4. Destructive static and dynamic testing, cross section and acoustic analysis were used as evaluation methods. The project results show the possibility of completely or partially replace adehsive joining with ultrasonic welding.

Expected results and effects

Laboratory scale evaluations and results of these implemented on the demonstrator reached TRL4. The results show the possibilities of implementing welding in whole or in part instead of gluing, i.e. welding points become load-bearing joints for vacuum formed materials. A total replacement with welding leads, according to sustainability assessment, to a reduced climate impact of 6%. Nevertheless, a replacement of adhesive joining leads to a significant improvement in the working environment, as not infrequently isocyanate-containing polyurethane-based adhesives are used.

Planned approach and implementation

Plan and outline of the project: AP 1 Requirements and evaluation AP 2 Technical evaluation in lab scale and quality control methods AP 3 Technical evaluation of demonstrators A 1-AP 3: Ultrasonic welding on sample coupons in ABS (vacuum format and injection molded) and PC-ABS, vacuum format. Results and data from testing and calculations contributed to a simulation model AP4 Business and environmental assessment: Themethod was studied from the perspective of sustainability assessment. A process-FMEA as well as a deeper cost analysis for the complete jointing process was dones.