BATTELLE RESEARCHERS DEVELOP IMPROVED PROCESS FOR POLYMER BONDING
May 16, 2005

BATTELLE RESEARCHERS DEVELOP IMPROVED PROCESS FOR POLYMER BONDING

Columbus, Ohio-Researchers at Battelle have developed a new, stronger method of joining materials together that conserves energy and minimizes material costs.

The patented process for Ultrasonic Injection Molding strongly bonds polymers and does so at significantly lower temperatures than those seen in traditional bonding processes that use heat alone. The secret is a relatively low level of ultrasonic energy applied to the polymer molding or polymer extruding process--specifically in the regions where inserts are placed or at intersections of two or more polymers.

Researchers believe the breakthrough may have the greatest impact in the automotive industry where a thin layer of high-performance, high-cost polymers can be bonded over low-cost substrates in plastic trim and body parts. Other potential applications include high-strength parts in mounting components for electronics, plastics enclosures and housings, and mechanical machinery covers and enclosures.

The combination of low cost and low temperatures is significant. Specifically, the lower temperatures allow uses with electronics that are difficult or impossible using traditional, high-temperature bonding.

"We believe this is a breakthrough with potentially significant performance improvement and cost reduction potential," says Lynn Faulkner, Program Manager at Battelle. "The process improves flow and mold filling, removes gas bubbles from the mold, eliminates cold bonds, and allows incorporation of filler materials."

Battelle is a global leader in science and technology. Headquartered in Columbus, Ohio, it develops and commercializes technology and manages laboratories for customers. Battelle, with the national labs it manages or co-manages, oversees 19,000 staff members and conducts $2.9 billion in annual research and development. Battelle innovations include the development of the office copier machine (Xerox), pioneering work on compact disc technology, medical technology advancements, and fiber optic technologies.

For more information, visit www.battelle.org or contact Media Relations Manager Mark Berry at (614) 424-5544 berrym@battelle.org, or National Media Relations Manager Katy Delaney at (410) 306-8638 delaneyk@battelle.org.