Düsseldorf, October 15, 2024 – Envalior is focusing its development activity on PBT compounds for laser transmission welding and plans to expand the corresponding product range. In doing so, it can rely on three proved technologies. “These three technologies allow us to offer an extremely versatile product range of laser-weldable Pocan® and Arnite® PBT compounds with a wide variety of properties. We are also working on new technologies for formulating laser-transparent PBT compounds that significantly increase the range of applications for this material class,” explains Lucas Lichius, Global Product Manager for PBT.
In addition to large-scale applications in the E/E, IT and consumer goods industries, Envalior is targeting trends such as e-mobility, 5G mobile communications and the digitalization of everyday life in particular. Potential uses include intricate housings for adaptive cruise control systems, battery control units for electric vehicles, GPS systems, cameras, air-conditioning systems and 5G antennas.
Laser transmission welding, also known as laser welding, will be one of Envalior’s key topics during Fakuma 2024 at the Exhibition Center Friedrichshafen, in Hall B4, Stand 4302, Oct. 15 to 19, 2024.
Laser transmission welding: how it works
Laser welding involves passing a short-wave infrared laser beam through a laser-transparent PBT component. The beam is then absorbed by a second, usually black-pigmented, component underneath. This generates heat that initially melts the surface of the second component, followed by the surface of the first component, thanks to thermal conduction. The melts of both joining partners mix and a material bond is created in the form of a weld seam. Laser welding is easily automated and subjects the components to less thermal and mechanical stress than vibration and infrared welding. It does not create any contaminating lint that needs to be cleaned out – like when half-shells are welded together to form liquid containers. 3D contours can be welded, as can hard-soft material combinations.
Cycle times are short and any expellation at the weld seam is negligible to non-existent. The weld seams boast a similar strength as the underlying materials. Thanks to these benefits, laser welding has recently enjoyed a significant upturn in popularity when it comes to welding small components with complex geometries, reflecting the trend toward miniaturized electrical and electronic functions.
Up to 300 percent higher laser transparency
Envalior’s product range for laser welding includes products reinforced with glass fibers (between 15 and 30 percent by weight), halogen-free flame-retardant, hydrolysis-stabilized, low-warpage, low-shrinkage, extremely heat-resistant, easy-flowing product types and as well compounds containing recycled materials. The XLT technology allows Envalior to formulate PBT compounds that offer optimum laser transparency and can be welded extremely quickly. One such example is Arnite® LT TV4 261. Comparative tests with radar housings have shown that this compound can be welded at least twice as quickly as standard PBT variants. As its laser transparency is around 300 percent higher, it can also be used to weld thicker components and components with higher glass fiber contents.
Best rating in the SAE/USCAR long-term hydrolysis test
Thanks to its LT technology (Laser Transparency), Envalior can offer PBT compounds with both outstanding hydrolysis resistance and good laser transparency. This is normally a contradiction, as these two properties have a negative influence on each other. One such material is already developed and ready for sampling. It is reinforced with 30 percent glass fibers by weight, test specimens of the material achieve “Class 5” – the best possible rating – in tests based on the stringent long-term hydrolysis tests of the US Society of Automotive Engineers (SAE/USCAR-2 Rev. 7).
Higher transmission with polycarbonate as the blending material
Envalior’s third technology for laser-transparent PBT compounds involves reducing the semi-crystalline content of the PBT and increasing laser light transmission by using amorphous polycarbonate as blending material. This is the case for Pocan® C3230LT. At a laser light wavelength of 980 nanometers, it achieves transmission that is almost twice as high as a comparable standard PBT (color black, test specimen thickness of one millimeter). Containing 30 percent glass fibers by weight, the low-warpage compound produces high-quality surfaces. It is suitable for applications with demanding optical requirements, such as visible electronics housings.
New technology path in development
Envalior is currently working to refine the three individual technologies for new products. “We are also pursuing a new technology path that will allow us to combine high laser transparency and good hydrolysis resistance with a wide processing window, thereby creating a stable and economical production process with short cycle times,” says Lichius.
For more information on the products and services provided by Envalior, visit www.envalior.com/en-us/products.html.
Envalior is focusing its development activity on PBT compounds for laser transmission welding and intends to expand the corresponding product range. Potential uses include intricate housings e.g. for adaptive cruise control systems, battery control units for electric vehicles, GPS systems, cameras, air-conditioning systems and 5G antennas.
Photo: Envalior
About Envalior
Envalior is a global leader in Engineering Materials with over 4,000 employees worldwide. It was established in 2023 through the merger of Lanxess Performance Materials and DSM Engineering Materials. With a long track record of customer-driven innovation, Envalior specializes in developing sustainable and high-performance material solutions. Focus markets include Automotive, New Mobility, Electronics & Electrical, and Consumer Goods. For more information, visit www.envalior.com.
Forward-Looking Statements
This company release contains certain forward-looking statements, including assumptions, opinions, expectations and views of the company or cited from third-party sources. Various known and unknown risks, uncertainties and other factors could cause the actual results, financial position, development or performance of Envalior GmbH to differ materially from the estimates expressed or implied herein. Envalior GmbH does not guarantee that the assumptions underlying such forward-looking statements are free from errors, nor does it accept any responsibility for the future accuracy of the opinions expressed in this presentation or the actual occurrence of the forecast developments. No representation or warranty (expressed or implied) is made as to, and no reliance should be placed on, any information, estimates, targets and opinions contained herein, and no liability whatsoever is accepted as to any errors, omissions or misstatements contained herein, and accordingly, no representative of Envalior GmbH or any of its affiliated companies or any of such person’s officers, directors or employees accepts any liability whatsoever arising directly or indirectly from the use of this document.
Candace Roulo
