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Joining Techniques
A Design Guide
DESIGNING FOR
ASSEMBLY AND DISASSEMBLY
This manual is intended to help you • Triax® polyamide/ABS blends; and To design good assemblies you
successfully design and manufacture must have:
assembled parts made of: • Centrex® ASA, AES and ASA/AES
weatherable polymers; • A working knowledge of the plastic
• Durethan® polyamide 6 and 6/6; resin you have selected;
• Lustran® ABS and ABS blends; Thermoplastics can be joined success- • A fundamental knowledge of good
fully in a number of different ways, joint design; and
• Lustran® SAN; including mechanical fastenings, ultra-
sonic assembly, metal inserts, snap fits, • A thorough understanding of the
• Pocan® PBT and PBT blends; electromagnetic and heat welding and purpose, geometry, ambient environ-
solvent/adhesive bonding. ment, chemicals, and mechanical
loading which your assembly will
encounter.
1
GUIDELINES FOR
JOINING TECHNIQUES
2
TABLE OF CONTENTS
24 Snap Fits
25 Press Fits
3
4
MECHANICAL FASTENING
Mechanical fasteners — screws, bolts SCREWS, BOLTS AND RIVETS Always make sure that there is suffi-
and rivets — offer one of the least cient distance between the edge of the
expensive, most reliable and commonly When using common mechanical meth- fastener’s hole and the part’s edge.
used joining methods for assemblies ods for securing parts, pay special atten- As a rule of thumb, this distance should
that must be taken apart a limited tion to the fastener’s head. Conical be at least the diameter of the hole or
number of times. Common practices heads, called flat heads, produce unde- twice the part’s thickness, whichever
for using mechanical fasteners are sirable tensile stress in the mating parts is greater.
discussed in this section. and should be avoided (see figure 1).
Bolt or screw heads that have a flat Additional clearance may be needed if
underside, called pan or round heads, your part has slotted holes for attaching
produce less harmful, compressive large plastic panels to metal or wood
Figure 1 stress. Use flat washers under both nut frames to account for the differing
and fastener heads, because these help coefficients of thermal expansion. See
distribute the assembly force over larger page 12 for a discussion of this topic.
Washer
areas (see figure 2).
Hex and
Square
Table 1 U.S. & Metric Threads
Common head styles of screws and bolts. 5/8-11 0.625 M16x2 0.630
3/4-10 0.750 M20x2.5 0.787
7/8-9 0.875 M22x2.5 0.866
5
Mechanical Fastenings Figure 2
Use
Washers
Use
Standoffs
MOLDED-IN THREADS If possible, avoid molded-in threads When designing parts with molded-in
when mating thermoplastics to metal. threads, consider the following factors.
When your application requires infre- These materials have large differences
quent assembly and disassembly, you in both stiffness and thermal expansion, • Thread Damage: Avoid feather edges
can use molded-in threads for mating and sharp edges of metal threads can on thread runouts to prevent cross
thermoplastic to thermoplastic parts also result in high stress in the thermo- threading and thread damage.
(see figure 3). For easier mold filling plastic part. Initial engagement and
and better part tolerances, avoid design- tightening will cause some stress and • Roots and Crests: Avoid sharp roots
ing parts with threads of 32 or finer should be checked to prevent tensile and crests on threads to reduce stress
pitch. Do not use tapered threads, such crazing or breaking. Stress relaxation of concentrations and make filling the
as pipe threads, unless you provide a plastic threads can lead to loosening of mold easier.
positive stop. Overtightening can cause a connection, and possibly part failure.
excessive stress following assembly that • Mold Cost: Internal threads, formed
can lead to part failure. by collapsible or unscrewing cores,
and external threads, formed by
split cores or unscrewing devices,
increase mold cost.
Figure 3 Molded-In Threads
1/ 32 1/ 32
in (0.8 mm) min. in (0.8 mm) min.
Roots
Rounded
Typical
Crests Radius
0.015 in
(0.381 mm)
6
MECHANICAL FASTENING continued
SELF-THREADING OR Figure 4
SELF-TAPPING SCREWS
7
Figure 5 For more information on self-threading
screws and their availability, contact:
0.3T max.
T
Screw Bosses
These boss designs for thread-cutting screws are based upon structural considerations.
Design screw bosses with care. While
Other design details addressing aesthetic considerations are available.
small boss diameters reduce the tenden-
cy for sinks and/or voids because they
have thin side walls, they may not pro-
vide sufficient structural strength to
withstand assembly hoop stress. See
figure 5 for suggested boss design.
A counterbore, provided as a lead-in,
helps align the screw and reduces hoop
stresses at the top of the boss, where
stress-cracking generally starts. Tables
2A through 2D list some average pull-
out forces and various torque data for
thread-cutting screws tested in selected
LANXESS resins. For this data, the
screws were installed in the manufacturers’
suggested hole diameters. The screw
boss outer diameter was approximately
twice the screw outer diameter.
8
MECHANICAL FASTENING continued
Table 2A Thread-Cutting Screw Data for Durethan BKV 130 30% GF Polyamide 6 Resin
9
Suggested Tightening Torque Figure 6
Self-Piercing/Self-Drilling Screws
15 1.7
Boss Caps
5 1.2 x Td 0.6
Td select the proper screw type for the
plastic material used because the wrong
screw may still crack a part even with
0 0 the use of a boss cap.
0 2 4 6 8 10
SCREW TURNS
Figure 7
* On-sert is a trademark of
The Palnut Company
908-233-3300
10
MECHANICAL FASTENING continued
Figure 8
Correct Incorrect
Four standard rivet heads for use with LANXESS thermoplastic resins.
Generally, thread lockers can be chemi- Self-locking steel fasteners and push-
cally aggressive to plastics. If you are on spring-steel fasteners, such as
using a thread-locking liquid to secure Tinnerman* nuts (see figure 9), offer
metal fasteners, fully test the liquid for another option for assemblies subjected
chemical compatibility with the thermo- to light loads. Usually pushed over
plastic material before production use. a molded stud, these fasteners are
Tinnerman* Thermoplastic
Self-Locking Stud Request a copy of Chemical frequently used in applications such as
Speed Nut
Compatibility Test for Unreinforced circuit boards. The plastic stud should
Thermoplastic Resins for further have a minimum 0.015 inch (0.38 mm)
information. radius at its base.
11
JOINING DISSIMILAR Where: Typically, as the temperature rises, the
MATERIALS Am = Coefficient of linear thermal stiffness of the plastic part decreases.
expansion of the metal With much higher temperatures, the
In a typical large plastic and metal Ap = Coefficient of linear thermal plastic part will eventually buckle. The
assembly where movement is restricted, expansion of the plastic resin opposite occurs when the temperature
high compressive or tensile stresses can Ep = Young’s modulus of elasticity for decreases: The plastic part shrinks,
develop. Figure 10A shows a large the plastic resin developing strain-induced tensile
plastic part fastened to a metal base or $ T = Change in temperature stress. With much lower temperatures,
bracket. As the ambient temperature stiffness increases even more and the
rises, the plastic will expand more than (When performing these calculations, a strain-induced stress approaches critical
the metal because the plastic has a consistent system of units is essential. levels, leading to part failure.
higher coefficient of linear thermal Use the temperature units specified
expansion. In this example, the plastic’s in “A.”)
expansion coefficient is four to six
times higher.
ST = (Am - Ap) • Ep • $ T
Metal
Bracket
Stiffener
12
MECHANICAL FASTENING continued
Bad
When joining plastic and metal parts, Result
tightening torque for the inserted screw
has important implications. Do not
tighten fasteners to the point where joint
friction and compressive loads prevent
relative movement. If the fasteners are
too tight, the effect of the slotted holes
will be negated, leading to possible part
failure.
Better
Result
The slotted hole and sliding attachment at one end of the plastic cover in the lower
assembly enables it to accommodate the thermal expansion difference with the metal base.
13
Coefficient of Linear Thermal Expansion (CLTE) Worked Example
Table 3 Values for Common Materials
14
MECHANICAL FASTENING continued
The total difference in thermal expan- Figure 10C Joining Dissimilar Materials
sion is 0.276 inch. Because we have two
assembly points, the movement between
fasteners is 0.276/2 or 0.138 inch. In Metal
Part
this example, you would have to plan
for a range of movement of 0.138 inch
at each fastening site. You must allow Soft
Washer
for this expansion in your design to pre-
vent stresses that could jeopardize the Fastener
Slotted
assembly, which can be estimated using Hole
Where:
Am = Coefficient of linear thermal
expansion of the metal
Ap = Coefficient of linear thermal
expansion of the plastic resin
Ep = Young’s modulus of elasticity for There are many “J” clips
and fasteners that will
the plastic resin allow relative movement
$ T = Change in temperature in assemblies.
Centrex 821
Panel
Aluminum
Stiffener
48 in
24 in
15
ULTRASONIC ASSEMBLY
Ultrasonic assembly, one of the most ULTRASONIC WELDING resin and melting the surrounding areas
widely used joining techniques for ther- slightly. The melted material from both
moplastics, makes permanent, aestheti- Ultrasonic welding is an excellent parts solidifies to create a permanent
cally pleasing joints. Four common bonding method for thermoplastics. bond.
ultrasonic assembly techniques — Generally, small amounts of fillers,
welding, staking, spot welding, ultra- such as fiberglass, will not inhibit weld- Design energy directors with an apex
sonic inserts — use high-frequency ing. If glass content in the resin exceeds angle from 60 to 90° (see figure 14).
mechanical vibration to melt mating 10%, some horn wear on the welding For thin-walled parts, a 60° energy
surfaces. This section discusses various device may occur. If glass content director may be more practical.
ultrasonic assembling techniques. exceeds 30%, the bond may be poor. Generally, the base width of the energy
Additionally, some external mold- director should not be more than 20 to
An ultrasonic plastic assembly system release agents, lubricants and flame 25% of the wall thickness supporting it.
converts standard electrical energy retardants will affect weld quality Figures 13 through 15 show a variety of
from 50/60 Hz to 20 to 40 kHz and then adversely. joint designs using energy directors.
into mechanical vibratory energy. A 40- (An energy director with a 90° apex
kHz machine produces an amplitude of The most important design feature in an angle creates more melt and will
one-half that of a 20-kHz unit, allowing ultrasonically welded joint, the triangu- improve joint strength marginally for
for a more gentle action. lar-shaped energy director, minimizes some semi-crystalline resins, such as
initial contact between the parts. During Durethan, Pocan and Triax.)
welding, the energy director tip melts
rapidly, filling the joint with molten
***Depth
of Weld
Melt Melt
Min.
Lead-In
0.030 in 30 – 45o
Interference
Fixture
Maximum Interference
Part Per
Dimensions Side
16
ULTRASONIC ASSEMBLY
1/ 3 W
17
Figure 16 ULTRASONIC INSERTS/
HEAT INSERTS
18
ULTRASONIC ASSEMBLY continued
Durethan
B 31 SK
Durethan
BKV 130
Lustran
448 ABS
LANXESS RESIN GRADE
Insert Size
#4
#6
Centrex
833 ASA #8
0 10 20 30 40 50 60
19
Average Pullout Force Figure 19B
Durethan
B 31 SK
Durethan
BKV 130
Lustran
448 ABS
LANXESS RESIN GRADE
Insert Size
Insert Size
#4
#6
Centrex
833 ASA #8
Inserts were supplied by: Spirol® Heat/Ultrasonic Insert An alternate way to install inserts
Spirol International Corporation instead of using ultrasonic energy is
Dodge Ultrasert II® Danielson, CT 06239 heat insertion. In this method, inserts
Emhart Fastening Teknologies (860) 774-8571 are heated to a predetermined tempera-
Shelton, CT 06484 ture, derived empirically for each insert
(203) 924-9341 Yardley Type H Intro Sert® and part. Much like ultrasonic inserts,
Yardley Products Corporation heat inserts are positioned via air pres-
P.S.M. Sonic-Lok 86 Series Yardley, PA 19067 sure. The plastic around the insert
IN-X Fastener Corporation (800) 457-0154 melts, causing a bond. Use the same
Fairfield, NJ 07004 basic guidelines for boss design and
(973) 882-7887 Barb-Sert® Insert installation as for inserts that are ultra-
Groov Pin Corporation sonically installed. Figures 20 and 21
Cliffside Park, NJ 07657 show pullout strength and stripping
(201) 945-6780 torque values for heat inserts.
20
ULTRASONIC ASSEMBLY continued
400
2900 Dukane Drive
350 St. Charles, IL 60174
300 (630) 584-2300
250
Forward Technology Industries, Inc.
200
Cokato, MN 55321
#4 #6 #8
(800) 286-2578
INSERT SIZE
Herrmann Ultrasonics, Inc.
Pull-out strength of heat inserts in Lustran 448 ABS. 620 Estes Avenue
Schaumburg, IL 60193
(847) 985-7344
Stripping Torque vs. Insert Size Figure 21
700
60
Ultra Sonic Seal Co.
650
368 Turner Industrial Way
600
50 Aston, PA 19014
550 (610) 497-5150
500
40
STRIPPING TORQUE (lb-in)
450
400
30
350
300
20
250
10
200
#4 #6 #8
INSERT SIZE
21
METAL INSERTS
If your part is going to be disassembled Before inserts are placed in a mold, they COIL-THREADED INSERTS
regularly, consider using metal inserts should be cleaned to remove foreign
for joining. Most inserts should be matter, including any oils or lubricants. Made into a coil of wire, coil-threaded
installed ultrasonically or with heat to Inserts should seat securely in the mold inserts provide greater wear resistance
minimize residual stresses (see page to prevent floating and possible damage and strength than the parent material
18). Use and installation suggestions to the mold. (see figure 22). However, they can also
for other types of metal inserts appear produce high stress in the boss or
in this section. Avoid inserts with sharp knurls or pro- receiving hole, which may lead to
trusions. Although they can have high boss failure.
pullout values, the sharp points cause a
MOLDED-IN METAL INSERTS notch effect in plastics that can lead to
early failure. THREAD-CUTTING INSERTS
Molded-in metal inserts can cause high
residual stresses in plastic bosses. Inserts larger than 0.25-inch (6.35-mm) With external cutting edges similar to a
Avoid inserts in parts made of diameter may induce excessive thermal tap, thread-cutting inserts (see figure
polycarbonate blends, because the stresses, which can be partially reduced 23) cut a clean, even thread when
residual stress may result in crazing, by preheating the insert to at least the inserted into a molded or drilled hole.
cracking and eventual part failure. current mold temperature prior to These inserts are usually installed with
Plastic, having much higher coefficients placing it in the mold. a tap wrench or a drill press and tapping
of thermal expansion than metal, head. Never use lubricants or cutting
shrinks around the insert and becomes fluids when tapping holes in plastic.
stressed at the interface because the
insert imposes a restriction. Because
glass-reinforced resins have thermal
expansion coefficients closer to those
of metals, problems with metal inserts
occur less frequently in these resins. Figure 22
Molded-in metal inserts have also been
used successfully in some nylons
(Durethan polyamide 6 and 6/6) and Notch
styrenic polymers, such as Lustran
ABS and Centrex resins. Always
thoroughly test all molded-in inserts in
end-use conditions prior to beginning
full production runs.
22
METAL INSERTS
Figure 23
L Recommended
Inch Sizes Metric Sizes Diameter Length Hole Size
Internal Internal
Thread Size Thread Size D (in) L (in) H (in)
D
4-40 M3x0.5 0.171 0.234 0.152 – 0.149
2o 6-32 M3.5x0.6 0.218 0.281 0.194 – 0.190
H 8-32 M4x0.7 0.250 0.328 0.226 – 0.222
10-32 M5x0.8 0.296 0.375 0.264 – 0.259
1.25
Times
Insert
Length
Tap-Lok® C-Series self tapping insert. Courtesy of Groov-Pin Corporation, Ridgefield, NJ 07657, (201) 945-6780
kN
Installed into slip-fit, molded or drilled
360 1.6
holes, expansion inserts have signifi-
cantly reduced mechanical performance
315 Durethan Nylon 1.4
compared to those installed with ultra-
PULLOUT FORCE (lb)
23
SNAP AND PRESS FITS
Figure 25 Designed into the geometry of mating disassembly (see figure 25 for an
parts, snap fits offer a very inexpensive, example of a cantilever-arm snap fit).
quick and efficient joining method.
L Press fits must be designed with great Although the suitability of any given
y
care to avoid excessive hoop stress in resin varies with part design and use,
h the assembly. This section discusses most plastics can be used for snap fits,
snap and press fits, giving common particularly if the design calls for a one-
y = Deflection
E = Strain design parameters for their use. time assembly. If the end use calls for
y = 0.67 •
EL2 repeated assembly and disassembly,
h
reduce the maximum strain to which the
SNAP FITS part is exposed.
Simple cantilever snap arm.
Figure 26 Maximum
0.033 diametrical
Example:
Example: interference for
Shaft OD
Shaft OD == 0.250
0.250 in
in
0.031 Durethan BKV 30
Hub OD
Hub OD == 0.450
0.450 in
in
in ÷÷ 0.450
0.250 in 0.450 in
in==0.55
0.55 polyamide 6 and
0.029 Interference
Interference ==0.0235
0.0235in/in
in/in steel press fits
0.0235 in/in
in/in xx0.250
0.250inin== 0.006 in Max. Dia. Interference
(solid shafts).
INTERFERENCE (in/in or m/m Shaft Dia.)
0.027
Du
re
0.025 tthha
ann
BBK
KVV
330
0.023 0ss
hha
aftf
tinit
not
oBK
0.021 BVK
Stee 3V0
ll S
Shhaaf 3h0
fttininto uhb
toDD ub
0.019 uurertehta
hnanBKBVK
3V03h0
uhbub
0.017
0.015
0 0.2 0.4 0.6 0.8 1.0
SHAFT OD/HUB OD
24
SNAP AND PRESS FITS
Figure 27 Maximum
0.090 diametrical
interference
0.080 for Durethan BKV 30
ds = Inside Shaft Diameter polyamide 6
Hollow ds/Ds = 0.8* Ds = Outer Shaft Diameter
0.070 press fits
(hollow shafts).
INTERFERENCE (in/in or m/m Shaft Dia.)
0.060
0.040
Hollow ds/Ds = 0.4*
0.030
Solid Ds/Ds = 0*
0.020
Solid Steel Shafts
PRESS FITS The example shown in figure 26 per- When using press fits:
mits only 0.006-inch diametrical inter-
Because press fits can result in high ference on the 0.250-inch shaft. Actual • Clean all parts to ensure that they are
stresses, use caution when choosing production tolerances of the shaft and free of any foreign substance, such as
this assembly method. Generally, do hub may vary enough to cause a slip fit lubricants or degreasers;
not use press fits as a primary joining — such that the part will not function as
method for parts made of LANXESS designed — or excessive interference, • Avoid press fits when the mating
resins. Figures 26 and 27 show maximum leading to high hoop stresses in the parts are made of two different mate-
diametrical interference recommended plastic hub. In the latter case, press fits rials and the part will be subjected to
for hubs made of Durethan resin when can cause cracking in polycarbonate thermal cycling; and
pressed onto either shafts of Durethan blends. Resins such as ABS and
polyamide 6 resin or steel. nylon (polyamide), can better tolerate • Avoid press fits if the assembly will
excessive interference; but they may be subjected to harsh environments
exhibit stress relaxation, leading to during manufacturing, assembly,
a looser fit over time. We suggest transportation or end use.
prototyping and thorough testing of all
press-fit assemblies.
25
HEAT WELDING AND SEALING
26
HEAT WELDING AND SEALING
Figure 29
Figure 22
Shear Joint
27
Figure 30 Figure 31 When the joint interface reaches a
molten state, the vibrating action is
stopped, parts are aligned, and clamp
pressure is briefly applied. Overall
cycle times for vibration welding are
usually 4 to 15 seconds (see figures 30,
31, 32 and 33 for joint designs).
SPIN WELDING
Butt joint. Flanged joint, for thin or long, unsupported
walls. You can weld round parts using spin
welding. Often a tongue-and-groove
joint design is used to align the two parts
and provide a uniform bearing surface.
Figure 32 Figure 33
a2 = 1.3 a1
To counteract inertial forces in some
Butt joint with flash trap. Variations with flash traps.
cases, the stationary part is allowed to
rotate with the moving part after the
mating surfaces have melted.
VIBRATION WELDING In this process, one part is fixed in a
stationary head, while the second part,
A friction-welding technique, vibration attached to a welding head, vibrates on
welding uses a machine that operates at the joint plane. Pressing the two parts’
a frequency of either 120 or 240 Hz surfaces together at a pressure of 200 to
with a small displacement of 0.030 to 245 psi (1.4 to 1.7 MPa) and vibrating
0.140 inch (0.7 to 3.5 mm). one against the other generates heat.
28
SOLVENT AND ADHESIVE BONDING
Solvent and adhesive bonding are prob- SOLVENTS because it has a slower evaporation rate,
ably the least expensive joining methods ABS/Polycarbonate Blends allowing for longer assembly times.
for permanent bonds. Solvent bonding Mixing methylene chloride and ethyl-
joins one plastic to itself or another type Suitable bonding solvents vary with ene dichloride in a 60/40 solution, a
of plastic that dissolves in the same sol- resin. You can bond parts made commonly used mixture, will give you a
vent. Typically, this process involves of ABS/polycarbonate blends using longer time to assemble parts than pure
treating the bonding area with the mini- methylene chloride or ethylene methylene chloride because of the
mum amount of solvent needed to soften dichloride. Methylene chloride's reduced evaporation rate.
the surfaces, then clamping the parts fast evaporation rate helps to
together until they bond. Adhesive prevent solvent-vapor entrapment for When using solvent-bonding techniques
bonding uses commercially available simple assemblies (see figure 34). For with these resins, some embrittlement
materials that are specifically formulat- complex assemblies that require more may occur. Parts can lose some of their
ed to bond plastic parts to themselves or curing time, use ethylene dichloride excellent impact strength at the weld joint.
other substrates. This section discusses
common bonding methods and practices
associated with these joining techniques.
50
40
30
0 20 40 60 80 100 120 140 160 180 200
Cure curves for polycarbonate resin @ 10/60 sec setup/clamp, 100 psi, lap-shear test.
*Parent strength is yield strength of the base resin.
29
A five to ten percent solution of poly- Styrenics Apply a thin film of solvent to one part
carbonate in methylene chloride helps only. Within a few seconds after apply-
to produce a smooth, filled joint Parts made of Lustran ABS, SAN ing the solvent, clamp parts together in
when the mating parts made of and Centrex polymers can be solvent a pressure fixture applying between
polycarbonate blends do not fit bonded using similar procedures and 100 and 500 psi for a minimum of
perfectly. Do not use this mixture to different solvents. Typically, use 60 seconds.
compensate for severely mismatched methylethylketone (MEK), acetone, or
joints. Increasing the concentration can a mixture of the two. Additionally, a Because ultimate bond strength is pri-
result in bubbles at the joint. paste made of MEK and the base resin marily a function of solvent concentra-
can be used to fill small gaps in a part tion on mating surfaces, control the
or assembly. elapsed time between application and
Polyester Blends clamping carefully. If too much evapo-
ration occurs before clamping, poor
Do not use solvent bonding with parts Safe Solvent Handling bonding will result. For critical applica-
made of polyester blends such as PET tions needing more durability, consider
and PBT/PET. Due to the high Be careful when using any of these adhesive bonding.
chemical resistance of these resins, solvents. You must refer to your
aggressive solvents must be used for solvent supplier’s Material Safety
bonding. These solvents can cause low Data Sheet for health and safety CURING SOLVENT-
bond strength. information and appropriate handling BONDED PARTS
recommendations, including the use of
proper protective equipment, for all of Cure parts bonded with methyl-
Polyamide and PA Blends the solvents discussed in this section. ene chloride that are ultimately
intended for room-temperature
Parts made of Durethan and Triax resins service for 24 to 48 hoursin a
can be solvent bonded using solutions BONDING PROCEDURES well-ventilated area at room tem-
of concentrated formic acid, alcoholic perature. Never cure these parts in an
calcium chloride, concentrated aqueous Mating surfaces should be cleaned and air-tight enclosure where solvent vapors
chloral hydrate, or concentrated alco- free of grease, dirt or foreign matter might be trapped. These vapors could
holic phenol and resorcinol. Adding before bonding. For optimum bonding, attack parts and embrittle them.
five to ten percent by weight of unrein- parts should be well mated with no
forced Durethan resin makes the sol- strains to ensure uniform pressure Tests indicate that methylene-
vents easier to use. In optimum bonding distribution across the entire bond area. chloride-bonded parts had 80 to
conditions, the bond strength after 90 percent of the ultimate bond strength
bonding approaches the resin’s normal after curing for one to two days (see
Use a minimum amount of solvent. For
strength. figure 34).
best results, only one surface needs to
be wet. Excessive solvent can cause
bubbling and “squeeze-out,” decreasing
the bond strength.
30
SOLVENT AND ADHESIVE BONDING continued
Table 5 Solvent Bond Curing Schedule ADHESIVE BONDING SYSTEMS UV-cured adhesives, excellent for trans-
parent materials such as Lustran
Adhesive bonding systems are among SAN, cure in seconds and
Sequential Part or the most versatile for joining plastic typically have high bond strength.
Holding Bond
Time Temperature parts to parts made of the same plastic, Two-part acrylic adhesives
8 hr 73°F (23°C) a different plastic or a non-polymeric usually show high bond strength. Use
12 hr 100°F (40°C) substrate. Generally, adhesives produce care in selecting these adhesives, as
12 hr 150°F (65°C) more consistent and predictable results some of their accelerators can be very
12 hr 200°F (93°C) in joints requiring strength and durabili- aggressive to polycarbonate
12 hr 225°F (110°C) ty than other joining methods. The wide blends (see table 6).
variety of modern adhesives ensures
that you can find an optimum system Prototype-test all parts to determine
for your application. a given adhesive's suitability.
When working with polycarbonate
blends, curing parts for elevated- A number of variables must be consid-
service use and maximum bond ered when selecting adhesive bonding Safe Adhesive Handling
strength is much more complicated. materials, including:
You may have to use a complicated You must refer to your adhesive
treatment schedule of gradually increas- • Chemical compatibility with the supplier’s Material Safety Data Sheet
ing temperatures for these applications plastic substrate; for health and safety information and
(see table 5). For example, if an assem- appropriate handling recommenda-
bly is going to operate in an ambient • Flexibility/rigidity requirements; tions, including the use of proper
temperature of 200°F (93°C), the bond- protective equipment, for any
ed parts should be cured at 73°F (23°C) • Environmental and temperature bonding system that you use.
for eight hours; then at 100°F (38°C) requirements; and
for 12 hours, 150°F (65°C) for 12
hours, and finally 200°F (93°C) for • Aesthetics.
12 hours. Smaller bond areas can cure
in shorter times, while large areas Generally, two-part epoxy and urethane
usually require longer times or smaller adhesives impart excellent bond
temperature intervals. strength for thermoplastic materials.
Cyanoacrylate-based adhesives can
Uncured parts suddenly exposed to produce quick bonds; however, cyano-
elevated-temperature service can suffer acrylates can be aggressive when used
complete joint failure. Generally, the with polycarbonate resins, especially if
highest cure temperature should be parts have high levels of molded-in
equal to or slightly higher than the and/or applied stresses. Additionally,
highest expected service temperature. cyanoacrylic adhesive can be brittle. If
your part will be subjected to bending
loads at the joint, you may want to
select a more ductile system.
31
Table 6 Adhesive Systems Suitable for Bonding LANXESS Thermoplastics
Resins
Lustran ABS
Lustran SAN
L Suitable adhesives
PC Blends
Durethan
Centrex
N Some cyanoacrylates can be
Triax
Type of agressive to polycarbonate and PC
Adhesive Suppliers blends, and some cure a brittle layer
which can significantly lower the
Epoxy (Two-Part) A, B L L L L L L
flexural and impact properties of the
Urethane (Two-Part) C, D, G L L L L L L substrate
Cyanoacrylate B, E N L L L L L
U Acetoxy-cure silicaones can be
Acrylic G L L N/A L L L agressive to styrenics and styrenic
Methacrylic L L L N/A L L L blends if the acetic acid fumes are
trapped in the joint
Silicone F U U L U U U
UV Cure B, H N/A N/A N/A N/A L N/A X Cannot be used with resins
Hot Melt E, M L L L L L L containing polycarbonate
A. 3M Adhesives Division E. Bostik Findley, Inc. I. Tacc International M. Henkel Adhesives Corp.
St. Paul, MN 55144 Middleton, MA 01949 Rockland, MA 02370 Elgin, IL 60120
(888) 364-3577 (978) 777-0100 (800) 503-6991 (847) 468-9200
Epoxies, Contact Tape, Hot Melts, (Customer Service) Hot Melts
Contact Adhesives Cyanoacrylates (877) 822-4685
N. 3M Industrial Tape and
B. Loctite Corporation F. GE Silicones J. SIA Adhesives Specialties Division
Rocky Hill, CT 06067 Waterford, NY 12188 Seabrook, NH 03874 St. Paul, MN 55100
(860) 571-5100 (518) 237-3330 (603) 474-2100, Ext. 205 888-364-3577
Epoxies, Cyanoacrylates, Silicones (Customer Service) Contact Tapes
UV Cures Vinyls
G. Vantico Incorporated
C. Ashland Chemical, Inc. Los Angeles, CA 90039 K. Macco Adhesives
Dublin, OH 43017 (800) 367-8793 Strongsville, OH 44136
(614) 790-3333 (Customer Service) (800) 634-0015
Urethanes (818) 247-6210 LIQUID NAILS®
Acrylics, Urethanes
D. Lord Corporation L. ITW
Erie, PA 16509 H. Dymax Corporation Des Plaines, IL 60016
(814) 868-3611 Torrington, CT 06790 (847) 299-2222
Urethanes (860) 842-1010 Methacrylics
UV Cures
32
SOLVENT AND ADHESIVE BONDING continued
33
TECHNICAL SERVICES
34
TECHNICAL SERVICES
The types of expertise you can obtain REGULATORY COMPLIANCE FOR MORE INFORMATION
from LANXESS include:
Some of the end uses of the products The data presented in this brochure
Design Review Assistance described in this publication must are for general information only. They
• Concept development comply with applicable regulations, are approximate values and do not
• Product/part review such as the FDA, USDA, NSF, and necessarily represent the performance
• Tooling review CPSC. If you have any questions on the of any of our materials in your specific
• Material selection regulatory status of these products, application. For more detailed informa-
• Finite element analysis contact your LANXESS representative tion, contact LANXESS Corporation
• Mold filling analysis or the Regulatory Affairs Manager in at (800) LANXESS, or your nearest
• Structural stress analysis Pittsburgh, Pa. district office.
The conditions of your use and applications of our products, technical assistance and information (whether verbal, written or by way of production
evaluations), including any suggested formulations and recommendations, are beyond our control. Therefore, it is imperative that you test our products,
technical assistance and information to determine to your own satisfaction whether they are suitable for your intended uses and applications. This
application-specific analysis at least must include testing to determine suitability from a technical as well as health, safety and environmental standpoint.
Such testing has not necessarily been done by LANXESS Corporation. All information is given without warranty or guarantee, and is subject to change
without notice. It is expressly understood and agreed that the customer assumes and hereby expressly releases LANXESS Corporation from all liability,
in tort, contract or otherwise, incurred in connection with the use of our products, technical assistance and information. Any statement or recommendation
not contained herein is unauthorized and shall not bind LANXESS Corporation. Nothing herein shall be construed as a recommendation to use any product
in conflict with patents covering any material or its use. No license is implied or in fact granted under the claims of any patent.
35
NOTES
36
LANXESS Corporation • 111 RIDC Park West Drive • Pittsburgh, PA 15275-1112 • 800-LANXESS
http://techcenter.lanxess.com
Sales Offices:
Canadian Affiliate:
Note: The information contained in this bulletin is current as of March 2006. Please contact LANXESS Corporation to determine
whether this publication has been revised.
Printed on recycled paper KU-GE028 Copyright © 2005, LANXESS Corporation Printed in U.S.A. 570 (25M) 04/00