Thermal Welding by the Third Phase Between Polymers: A Review for Ultrasonic Weld Technology Developments.

Area of Science:

• Materials Science
• Polymer Science
• Manufacturing Engineering

Background:

• Ultrasonic welding (USW) is a key technology for joining dissimilar materials.
• Traditional USW faces challenges with certain polymer combinations.
• The ultrasonic thermal welding by the third phase (TWTP) method offers an improved approach.

Purpose of the Study:

• To review advancements in applying ultrasonic TWTP for thermoplastic materials.
• To summarize research on TWTP for specific polymer pairs (PC/PMMA, PLA/POM, PLA/PMMA).
• To provide guidance on TWTP in polymer welding and elucidate its mechanism.

Main Methods:

• Review of existing research on ultrasonic TWTP for dissimilar polymers.
• Analysis of studies focusing on third-phase preparation, weld strength, and surface morphology.
• Examination of thermal stability and other properties of TWTP-welded polymers.

Main Results:

• TWTP demonstrates superior effectiveness for welding dissimilar polymers compared to traditional USW.
• Specific polymer combinations like PC/PMMA, PLA/POM, and PLA/PMMA have been successfully welded using TWTP.
• Key factors influencing weld quality, including third-phase formation and interdiffusion, have been investigated.

Conclusions:

• Ultrasonic TWTP is a highly effective technology for dissimilar polymer welding.
• Understanding the interdiffusion and molecular motion mechanisms is crucial for optimizing TWTP.
• This review provides a foundation for further development and application of TWTP in polymer manufacturing.