What is the Hybrid-LTW® method?

 In October 2016, we announced the Hybrid-LTW® method as a type of welding method, particularly for large-size parts.
 This method had already been developed almost at the same time as the development of the ACW® method (absorbance control method)1) announced by Orient Chemical Industries, Ltd. in 2007. As the challenges of laser transmission welding have surfaced, now we have come to propose this method because it meets the users’ needs.
 This is a new method that has features of both the LTW method (laser transmission welding) and the ACW® method (absorbance control method).
 The Hybrid-LTW® method consists of two optically-different resin compositions: material transmitting laser (irradiation layer or transmission layer) and material absorbing laser (absorption layer) as shown in Figure 1.
 - Side of material irradiated with laser
 -> light transmitting composition used in the ACW® method (ACW® composition)
 - Absorbing material
 -> widely-used black standard forming material or “eBIND® LAW®-series” that we propose
 By using these materials, optimization is possible.
 [Figure 1 What is the Hybrid-LTW® method?]
 (1) Tolerates gaps.
 In the method to weld resin with laser, shrinkage or warping caused by forming process produces a gap at the bonding portion, causing a welding defect.
 In this method, as a light-transmitting composition (ACW® composition) is used on the laser irradiation side, laser light heats the inside of the resin, penetrates deeper while melting the resin, and expands. 
 In an ordinary laser transmission method, the welding strength lowers when a 0.05-mm gap is present, and even when the gap is 0.1 mm, welding is impossible. However, when using the Hybrid-LTW® even when a gap of 0.05 mm was present, a welding strength equivalent to that obtained by ordinary laser transmission welding with no gap could be obtained successfully.
 (2) Optimum for welding of large-size parts
 As the Hybrid-LTW® method tolerates gaps, it is advantageous for welding large-size parts and parts with low surface accuracies.
 (3) Energy-saving and shortened tact time
 Unlike welding between light-transmitting compositions (ACW® composition), this method utilizes a light-transmitting composition in the irradiation layer only to increase the heat conduction and calorific value of the light absorbing composition. As a result, lower energy consumption and shorter tact time compared to ACW® method can be achieved.
 (4) High welding strength
 In this method, as a light-transmitting material is used as the material to be irradiated by laser, laser light heats the inside of the resin, penetrates deeper while melting the resin, and expands.
 With the Hybrid-LTW® method, in which a large molten pool is formed due to the above process, it is possible to obtain a higher welding strength (tension shear strength) than in an ordinary laser transmission method.
 (5) Acquisition of patent for the Hybrid-LTW® method
 Orient Chemical Industries, Ltd. has acquired the patent right concerning the Hybrid-LTW® method. To effectively use the patent right, we are proactively conducting licensing activities.

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