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AIP Conference Proceedings [American Institute of Physics PROCEEDINGS OF PPS-29: The 29th International Conference of the Polymer Processing Society - Conference Papers - Nuremberg, Germany (15–19 July 2013)] - In mold laser welding for high precision polymer based optical components

DOI:10.1063/1.4873764 出版年份:2014 更新时间:2025-09-12 10:27:22
摘要: To Assemble a complete subsystem as a rear lamp, is necessary to have different machines and to perform several tasks. This necessity obliges the companies to have large structures to support all the assembling process. These huge structures are very costly and have as a consequence the reduction of the competitiveness of the companies. The process presented in this document has the intention of reducing the number of tasks needed to produce the final subsystem/product. To achieve this goal were combined several technologies, as in-mould assembling, laser welding and LEDs (light-emitting diode). One of the advantages of this process was the utilization of only one injection molding machine with three injection units to do all the assembling process. To achieve the main objective, firstly, the rear lamp was designed according to with the legislation of UNECE Vehicle Regulations - 1958 Agreements; Regulation No. 50 -Rev.2 - Position lamps, stop lamps, direction indicators for motorcycles. Posterior several polymeric materials were studied at different levels. Initial were studied several concentrations of carbon nanotubes mixed with PC (polycarbonate). This had the objective of determine, if these materials are suitable to conduct the necessary electric current to turn on the different LEDs. One of the main advantages of this process is the use of the laser transmission welded process. Since, with this welding technology is possible reduce the complexity of the final part. To understand the potentialities of this technology a combination of two materials was studied. The studied showed that all materials presented a high transparency to the laser beam. In terms of weld process, the study showed that the best welding conditions are the lowest velocity, diameter and power. With these studies was possible conclude that this new process is suitable to be implemented at the industrial level.
作者: N. Oliveira,A. J. Pontes
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To study the combination of in-mold assembling and laser transmission welding processes for assembling high precision polymer based optical components, specifically a rear lamp, to reduce the number of tasks and machines needed in the production process.

The study concluded that the combination of in-mold assembling and laser transmission welding is suitable for industrial implementation. The best welding conditions were found to be the lowest laser velocity, diameter, and power. The use of PC mixed with 5% of carbon nanotubes was identified as the best conductive material for the application. Specific structures like pillow lens and reflection cavities were designed to meet legislation requirements for the rear light.

The study found that materials with a difference in their melting temperature of 50oC cannot be welded using the laser technology. Additionally, the process requires precise control of welding conditions (velocity, diameter, and power) to achieve optimal seam resistance.

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