Fabricating of SUMIKAEXCEL PES

Adhesives

Commercial off-the-shelf adhesives can be utilized for SUMIKAEXCEL PES (see Table 1).

Table 1 Adhesion

Type of Adhesive Adhesive Name Manufacturer
Epoxy-based 2-component Araldite Eco- AW136、AV138 Chiba-Geigy Japan
Eco-bond 104、144B Emerson & Cumming Japan
Amicon 316 Grace Japan
1-component Sumimac ECR9000 Series Sumitomo Bakelite
Araldite XN1244 Chiba-Geigy Japan
Technodyne AH-3063R Taoka Chemical
Rubber-based Hamatite PL605-50 Yokohama Rubber
Polyimide Thermoket CS-170 Toray
Table 2 Bond Strength of Each Adhesive (Units : MPa)
Adhesive Curing Conditions 4100G 4101GL30
Araldite AW136、AV138 120 deg C×1hr 3.0
Eco-bond 104 180 deg C×1hr 5.4 8.8
Eco-bond 144B 150 deg C×1hr 2.0 3.5
Amicon 316 150 deg C×1hr 3.2 7.4
Sumimac ECR9000 Series 100 deg C×1hr 4.6 6.7
Hamatite PL605-50 250~300 deg C×5min 13.0
Thermoket CS-170 70 deg C×1hr→180 deg C×3hr 4.1 8.1

Ultrasonic Welding

As SUMIKAEXCEL PES is an amorphous resin, an ultrasonic welding is relatively easy to perform if both pieces to be bonded are made of SUMIKAEXCEL PES. Three welding combinations are possible:
1.Both pieces are natural grades.
2.A natural grade is to be bonded to a fiber reinforced grade.
3.Both pieces are fiber-reinforced grades.
Case 1 is the easiest to accomplish and results in the greatest weld strength. However, cases 2 and 3 have adequate weld strengths and have better weld characteristics than crystalline resins (i.e.: PPS).
The conditions for ultrasonic welding will vary, depending upon the output of the welding horn, the product shape, weld area and grade. The standard conditions are as follows:

Table 3 Standard Conditions for Ultrasonic Welding

Pressure(MPa) 30~60
Amplitude(μm) 50~80
Welding Time(sec.) 0.1~2.0

Measurements of SUMIKAEXCEL PES shear strength after ultrasonic welding are shown below. The test method and test specimens used, are as follows:

Ultrasonic Welder
SONOPET-1200B (Seidensha Electronics Co., Ltd.)

Nominal Rating : 1200W
Oscillation Frequency : 19.5kHz
Welding Force : 75%
Amplitude : 34μm

Figure 1 Test Specimen for Measuring the Shear Strength of Welded Areas

Figure 1 Test Specimen for Measuring the Shear Strength of Welded Areas
Table 4 Shear Strength of Welded Areas (Unit : N)
  Oscillation Time (sec.)
0.1 0.2 0.3
PES 3600G 680 700 Rupture occurred in area other than the welded area.
PES 3601GL20 660 850 Rupture occurred in area other than the welded area.
PES 3601GL30 740 830 Rupture occurred in area other than the welded area.
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