In the work that combines plastic parts, the term “plastic welding” refers to the connection of two such parts to each other, permanently. What does this mean in practice, for what purposes are plastics welded and what are the differences in welding different types of plastics? All of these will be answered immediately.
First, we note that we are talking about joining thermoplastic plastics in particular and not plastics in general. Thermoplastics are types of plastic that can be changed after their production, since they melt under the influence of heat, unlike Thermosets (also called thermosetting polymers). The goal in plastic welding is to connect plastic parts in such a way that the product will be equivalent to a pre-connected part. That is, to connect the two parts as if they were not separated. This is expressed, among other things, in several parameters:
· Strength at the connection point: The connection points should be at least as strong as the strength of the original part, if not more. This depends on a good adaptation of the welding technique to the situation and the quality of the welding.
General condition of the product – that the product or the welded part will not be damaged in one way or another, due to the connection process.
The appearance of the object – sometimes the appearance of the product or the resulting object is also important. In any case, a good plastic joint should and can, by today’s means, also be aesthetic.
Plastic is a material whose nature provides many possibilities. It is possible to create many shapes from it and provide it, as needed, with a variety of different properties. The ability to weld plastic adds more possibilities to this – these are some prominent examples of this:
Production and handling of pipes: Plastic piping is a field in which plastic welding is particularly widely expressed, such as for example the production and handling of such piping for the construction industry.
Product packaging in factories: the ability to quickly connect plastic packaging parts regularly (until the product reaches the customer who will open the packaging). Thanks to this, you can save on adding another part that will serve as a means of fastening and closing the two parts together.
In the aviation industry: the world of aviation is a field where maximum precision and strength are required. This is also an industry where you see quite a bit of expensive and advanced equipment being used. So plastic welding techniques are applied quite a bit, including the most sophisticated ones.
In the sailing world: in the construction and repair of vessels there is an understandable preference for light and moisture-resistant materials and plastic is an ideal solution in many cases.
In the automotive field: modern vehicles include quite a few plastic parts. Thanks to plastic welding, it is possible to repair damaged car parts in a fast and affordable way compared to buying a new part and installing it. By the way, bumpers are based on plastic, among other things because their flexibility (compared to metal) helps reduce accident damage. Plastic welding for car repairs is part of a collection of sophisticated techniques developed to quickly repair the part instead of replacing it, similar to the quick repair of dents in tin parts, following a blow.
As you may have noticed, the typical purposes of plastic welding can be divided into several main types. It can be said that this is required in these processes:
· Production: as part of production processes to connect parts. Plastic welding makes it possible to quickly connect different parts in a new product. It may fit into production lines quite effectively. This is thanks to the fact that today there is a selection of plastic welding machines and that such processes can be controlled in a very precise and computerized manner.
·Repair: as part of repairing a defect in plastic, to fuse fractures and cracks.
Modification: to make a change to an existing product, such as an extension of a plastic pipe.
Besides gluing plastic parts or mechanically connecting plastic parts to each other, you can also connect plastic parts in these ways:
A method of connecting plastic parts, which is based on adding a connecting material. This is similar to soldering in the field of electronics where tin is used.
In welding, plastic parts are connected without a connecting material – the desired connection area is heated, so that the plastic melts a little and can now be connected. Plastic welding can be done using a variety of techniques and methods, examples of which will be given below. The welding technique must be adapted to the different types of plastic, since “plastic” is actually a general name for a wide variety of materials. There are plastic materials that are easier to solder and there are some that are more challenging. But the technology in this field today provides solutions for every situation. The welding method saves the need to add materials or connection aids. This is quite significant in that it simplifies processes and also prevents an increase in weight and thickness of the connected area. Enlarging the nose may in some cases interfere with its reassembly into an assembly or even its use. For the most part, such soldering can be done quite quickly and this is significant when a lot of repetition of such processes is required. A very important aspect is the strength of the connection – the soldering provides a very strong result, thanks to the fact that it actually creates a complete connection. Two parts that are connected in this way become one part for everything. This, unlike, for example, a connection with glue or screws, which may loosen over time.
Injection molding is a very common method for creating various plastic products. For injection there are advanced options such as injection of two materials on the same product (two-component injection). In fact, plastic injection is a fairly sophisticated field. Therefore, to get the full benefit from it, it is important to work with professionals. A good example of this is the plastic injection department of YSR Plastic Industries.
Over the years, a variety of plastic welding methods have been developed. These are examples of some of the most prominent methods today:
Ultrasonic welding is an old and very effective method, in which the plastic parts to be joined are heated. It is a fairly fast heating using sound waves. Another heating connection method is using a heated “plate”.
A laser is also known to be a means by which plastic can be heated quickly. Plastic laser welding is done by using such a beam to connect the parts in an extremely precise and clean manner. The beam passes through one part (transparent) and hits the other part. The connection area between the two parts heats up and the desired quick connection effect is obtained.
A special heating method in which one part is quickly moved, which is adjacent to a static part to which it is supposed to connect. The relative motion naturally causes strong friction, which creates a lot of heat.
Plastic welding is not a subject that stands alone, it is very broad and full of possibilities. In a broad view of professional treatment in the field of plastics, it is good to have one, reliable and high-quality address, we at YSR Plastic Industries are here to provide you with this service.
Since 1978, YSR Plastic Industries has established itself as a leading entity in the field of plastic injection moulding. We specialise in the production of complex and high-quality components, providing bespoke technological solutions to a diverse range of sectors. Operating both nationally and internationally, our reach extends across industries such as Electronics and Telecommunications, Defence and Aerospace, Medical Devices, Irrigation and Agriculture, Consumer Goods, Construction, and Infrastructure.
As a one-stop shop, we offer full turnkey solutions including procurement, sourcing, assembly, kitting, packaging, storage, and shipping. Our extensive facilities, covering 15,000 sqm with huge storage facilities and more than 100 employees, showcase our scalability.
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