Envalior expands PBT-compounds for laser transmission welding

• A broad and versatile product range based on three technologies proven in mass production.
• Technologies can be used in many applications, including complex housings for e-mobility, driver assistance systemsSmart homes and digitalization.
• The product range offers high laser transparency, a fast welding process, and excellent hydrolysis resistance under hot conditions.
• Laser transmission welding is one of Envalior's main topics at Fakuma 2024.

Düsseldorf, October 15, 2024 – “These three technologies make it possible for us to offer an extremely versatile range of laser-weldable Pocan® and Arnite® PBT compounds with a wide array of properties. We're also developing new technologies to formulate laser-transparent PBT compounds that greatly expand the range of applications for this material class,” explains Lucas Lichius, Global Product Manager for PBT.

In addition to large-scale use in the E/E, IT, and consumer goods sectors, Envalior is specifically focusing on trends like e-mobility, 5G mobile communications, and the digitalization of everyday life. Potential applications include intricate housings for adaptive cruise control systems, battery control units for electric vehicles, GPS systems, cameras, air conditioning units, and 5G antennas.

Laser transmission welding, also known as laser welding, will be one of Envalior’s key topics at Fakuma 2024 at the Exhibition Center Friedrichshafen, Hall B4, Booth 4302, October 15–19, 2024.

Laser transmission welding: how it works

Laser welding works by passing a short-wave infrared laser beam through a laser-transparent PBT component. The beam is then absorbed by a second, usually black-colored, part underneath. This creates heat that first melts the surface of the second part, and then the surface of the first part through heat conduction. The melts from both parts mix, and a material A bond is created in the form of a weld seam. Laser welding can be easily automated and puts less thermal and mechanical stress on components compared to vibration and infrared welding. It also doesn’t produce any contaminating lint that needs to be cleaned out—like when half-shells are welded together to form liquid containers. 3D contours and hard-soft material combinations can also be welded.

Cycle times are short and any material expelled at the weld seam is minimal to nonexistent. The weld seams have similar strength to the base materials. Thanks to these advantages, laser welding has recently become much more popular for welding small components with complex shapes, following the trend towards miniaturized electrical and electronic functions.

Up to 300 percent higher laser transparency

Envalior’s laser welding product range includes glass fiber-reinforced products (between 15 and 30 percent by weight), halogen-free flame retardant, hydrolysis-stabilized, low-warpage, low-shrinkage, extremely heat-resistant, easy-flowing types, and compounds containing recycled materials. XLT technology enables Envalior to formulate PBT compounds with optimal laser transparency that can be welded extremely fast. For example, Arnite® LT TV4 261. Comparative tests with radar housings have shown this compound can be welded at least twice as fast as standard PBT variants. With about 300 percent higher laser transparency, it can also be used to weld thicker parts and parts with higher glass fiber content.

Best rating in the SAE/USCAR long-term hydrolysis test

Thanks to its LT technology (Laser TrTransparency), Envalior can offer PBT compounds with both outstanding hydrolysis resistance and good laser transparency. This is normally a contradiction, as these two properties have a negative influence on each other. One such material is already developed and ready for sampling. It is reinforced with 30 percent glass fibers by weight, test specimens of the material achieve “Class 5” – the best possible rating – in tests based on the stringent long-term hydrolysis tests of the US Society of Automotive Engineers (SAE/USCAR-2 Rev. 7).

Higher transmission with polycarbonate as the blending material

Envalior’s third technology for laser-transparent PBT compounds involves reducing the semi-crystalline content of the PBT and increasing laser light transmission by using amorphous polycarbonate as the blending material. This is the case for Pocan® C3230LT. At a laser light wavelength of 980 nanometers, it achieves transmission that is almost twice as high as a comparable standard PBT (color black, test specimen thickness of one millimeter). Containing 30 percent glass fibers by weight, the low-warpage compound produces high-quality surfaces. It is suitable for applications with demanding optical requirements, such as visible electronics housings.

New technology path in development

Envalior is currently working to refine the three individual technologies for new products. “We are also pursuing a new technology path that will allow us to combine high laser transparency and good hydrolysis resistance with a wide processing window, thereby creating a stable and economical production process with short cycle times,” says Lichius.

About Envalior

Envalior is a global leader in Engineering Materials with over 4,000 employees worldwide. It was established in 2023 through the merger of Lanxess Performance Materials and DSM Engineering Materials. With a long track record of customer-driven innovation, Envalior specializes in developing sustainable and high-performance material solutions. Focus markets include Automotive, New Mobility, Electronics & Electrical, and Consumer Goods. For more information, visit www.envalior.com.

​​Forward-Looking Statements

This company release contains certain forward-looking statements, including assumptions, opinions, expectations and views of the company or cited from third-party sources. Various known and unknown risks, uncertainties and other factors could cause the actual results, financial position, development or performance of Envalior GmbH to differ materially from the estimates expressed or implied herein. Envalior GmbH does not guarantee that the assumptions underlying such forward-looking statements are free from errors, nor does it accept any responsibility for the future accuracy of the opinions expressed in this presentation or the actual occurrence of the forecast developments. No representation or warranty (expressed or implied) is made as to, and no reliance should be placed on, any information, estimates, targets and opinions contained herein, and no liability whatsoever is accepted as to any errors, omissions or misstatements contained herein, and accordingly, no representative of Envalior GmbH or any of its affiliated companies or any of such person’s officers, directors or employees accepts any liability whatsoever arising directly or indirectly from the use of this document.