A case study about how a light-curable adhesive replaced a two-part epoxy for faster sensor assembly and improved the application process. ...
Electrical Explosion Protection & Sensor Technology
A world leader in electrical explosion protection and sensor technology was looking to turn away from laser welding for an application that requires sealing two polycarbonates of their photoelectric sensors.
Challenge
Finding an alternative solution to laser welding for bonding a PC PCBA holder to a PC clear cover in a photoelectric sensor.
The customer was bonding PC covers to PC PCBAs by laser welding. However, they were unsatisfied with the results, as laser welding between PC and PC gives inconsistent bond results and lower units per hour (UPH). It also requires large laser weld equipment that takes up a lot of floor space. Our Dymax Application Engineers recommended using light-curing adhesives to replace the current laser weld process.
Solution
Dymax 3094-GEL-REV-A provided the best bonding results by providing IP67 ingress protection and meeting reliability requirements.
To support the customer in finding the most suitable light-curing adhesives and curing equipment for the process, the AE team tested several materials with customer parts in our laboratories and found that 3094-GEL-REV-A provided the best bonding strength when being cured with a 5000-EC flood curing system. This curing system offers high-intensity curing energy over a 5x5 inch area and 5-30 second cure times (typically) when using Dymax light-curable materials. Dymax application engineers optimized the process and provided the solutions to the customer, who was pleased with the test results and decided to put 3094-GEL-REV-A into their production qualification process.
Results
The customer improved their process by achieving better bonding and higher UPH.
The parts built with 3094-GEL-REV-A passed the customer’s reliability requirement for IP67 ingress protection, thermal cycling at -40°C to 70°C, and damp-heat soaking at 70°C/90%RH. The customer was satisfied with the results and proceeded to qualify the low-stress active bonder 3094-GEL-REV-A to replace the laser welding process. Dymax solutions system provided them with faster UPH and reduced the production floor space.
Related Products
Check out the other Dymax products that work in conjunction with this one to create a complete solution
Product Number
Product Description
Regional Availability
3094-GEL-REV-A
Low-stress plastic adhesive quickly bonds and seals a variety of plastics. This thixotropic and jet friendly material cures within seconds upon exposure to UV/Visible light.
Light-Curing Equipment
LED/UV/Visible light-curing equipment for manufacturing. Dymax portfolio consists of spot lamps, flood lamps/focused beam, conveyor systems, and accessories.
Dispensing Equipment
Dymax manual and automated fluid dispense systems and spray valves are easily integrated into existing manufacturing processes for easy application of coatings, lubricants, or masking resins.
Check out the other Dymax products that work in conjunction with this one to create a complete solution
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