Welding of SUMIKAEXCEL PES

Since SUMIKAEXCEL PES is an amorphous resin, it is relatively easy to weld SUMIKAEXCEL PES to itself using a variety of methods. Table 5-2-1 shows the typical welding methods that can be used to weld SUMIKAEXCEL PES and their characteristics. Since the characteristics differ depending on the welding method, it is necessary to select a method taking into consideration the size and shape of the product, the characteristics required for the product, and economic efficiency (equipment price, cycle, etc.).

Table 5-2-1 Welding of SUMIKAEXCEL PES

Welding Method Hot plate welding Ultrasonic Welding Vibration Welding Laser welding IR welding CVT (IR + vibration welding)
Weldability Welding Strength ◎※ ◎ ◎※ ◎ ○ ◎
Appearance of the welded part △ ○ ○ ◎ ◎ ◎
Weldable resin Thermoplastic Thermoplastic Thermoplastic Light-transmitting resin
Light absorbing resin		 Thermoplastic Thermoplastic
Welding Time 10 to 30 seconds 0.1 to 5 seconds 2 to 10 seconds 2 to 15 seconds 10 to 30 seconds 5 to 30 seconds
Weldable size Heater Size Business card size Pallet Size Approximately A3 size Instrument panel size Instrument panel size
Design Product shape restrictions Heater shape fundamentally Some degree of three-dimensional shape High degree of freedom Vibration welding High degree of freedom
Welding Design Exclusive Design Exclusive Design Exclusive Design Exclusive Design Exclusive Design Exclusive Design

*Welding may not be possible due to the high softening temperature of PES.

Since SUMIKAEXCEL PES is an amorphous resin, it is relatively easy to ultrasonically weld SUMIKAEXCEL PES to itself. There are three possible welding combinations:

  1. Non-reinforced grades
  2. Unreinforced and fiber reinforced grades
  3. Fiber reinforced grades

Option 1 is the easiest and also provides the greatest welding strength. However, options 2 and 3 also provide sufficient welding strength, and are superior to crystalline resins (e.g. PPS).
The ultrasonic welding conditions vary depending on the horn output, product shape, welding area, grade, etc., but the standard conditions are as follows.

Table 5-3-1 Standard conditions for ultrasonic welding

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

The measurement results of shear strength after ultrasonic welding are shown below. The test method and test pieces are as follows:

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

Nominal output: 1200W
Oscillation frequency: 19.5kHz
Pressure: 18N
amplitude: 34μm

Figure 5-3-1 Test piece for measuring the shear strength of welded joints

Figure 5-3-1 Test piece for measuring the shear strength of welded joints

Table 5-3-2 Maximum load at the time of weld failure (tensile shear test)

(Unit: N)

  Oscillation time (sec.)
0.1 0.2 0.3
3600G 680 700 Breaking outside the welded area
3601GL20 660 850 Breaking outside the welded area
3601GL30 740 830 Breaking outside the welded area

Laser welding is a method of welding by irradiating a laser beam and generating heat at the interface with the object. Laser resin welding combines a "light-transmitting resin (0.5 mm thick)" with a "light-absorbing resin (0.8 mm thick)." SUMIKAEXCEL PES has excellent light transmittance, making it possible to use laser welding.

Figure 5-4-1 Laser welding test conditions

Figure 5-4-1 Laser welding test conditions

Table 5-4-1 Laser welding strength

Grade Laser conditions (Φ0.6) Welding Strength
(MPa)
Light-transmitting resin
(Thickness 0.5mm)		 Light absorbing resin
(Thickness 0.8mm)		 output
(W)		 Movement Speed
(mm/s)
4100G 4100GB 3 10 30
15 33
20 34
3601GL20 3601GL20B 3 10 38
15 37
20 37