研究目的
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.
研究成果
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.
研究不足
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.
1:Experimental Design and Method Selection:
The study combined in-mold assembling and laser transmission welding technologies. The rear lamp was designed according to UNECE Vehicle Regulations. Several polymeric materials were studied, including concentrations of carbon nanotubes mixed with PC to determine suitability for conducting electric current to LEDs.
2:Sample Selection and Data Sources:
Materials used included PC (polycarbonate) and PMMA (polymethyl methacrylate) for their high impact resistance and similar glass transition temperatures.
3:List of Experimental Equipment and Materials:
A spectrophotometer Shimadzu UV-3101PC UV-VIS-NIR for NIR spectroscopy, universal test machine Instron model 4505 for mechanical tests, and a Lupe Stereoscopic Nikon SMZ-10 with digital camera Olympus DP11 for microscopic analysis.
4:Experimental Procedures and Operational Workflow:
The study involved determining the best welding conditions through mechanical tests according to norm EN 12814-3, studying the influence of welding velocity, diameter, and laser power variables based on DOE methodology.
5:Data Analysis Methods:
The influence of each variable was determined based on the difference between higher and lower values, with mechanical resistance and standard deviation analyzed for different welding conditions.
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