Bonding / potting & sealing



Electronics

Potting/sealing and bonding with the aid of UV technology are indispensable processes in electronics manufacturing today. They are reliable solutions for ever decreasing cycle times and increasing quality requirements. A wide range of UV systems is used, depending on the specific application. According to the adhesive or potting/sealing compound used, there is a choice between conventional technology with gas discharge lamps and IR-free UV LED technology.

Adhesive dots on sensors, electric motors and smartphones or potting/sealing points on plugs, rotary position transducers, coils, RFID chips or smartcards can be cured in a matter of seconds using high-intensity point source emitters. Flood lamps are used for curing larger areas, for example when bonding display screens or potting/sealing circuit boards (conformal coating). Optimised reflector geometries or the uniform arrangement of LED flood lamps provide good homogeneity, ensuring that these areas are cured without tension and evenly. This allows compliance with the most stringent quality standards, even in the case of large exposure areas.

Adhesive beads, for example in corner bonding, are cured using high-intensity line lamps.

Depending on the heat-sensitivity of the components, conventional UV systems use IR filter and reflector technology to achieve a marked reduction in the temperature load.

From mobile production using hand-held lamps to small-series production in irradiation chambers right through to fully automated production lines with PLC control, Hönle UV technology has the ideal solution.

All Hönle UV and UV LED systems are precisely tailored to the UV-reactive adhesives and potting/sealing compounds made by Panacol, a Hönle Group company, ensuring a one-stop, process-reliable system solution.

 

Examples of bonding applications:

  • Display bonding
  • Display sealing
  • Loudspeaker/microphone bonding
  • Sensors
  • Corner bonding
  • Rotary position transducers
  • Sensor bonding
  • Bonding of electric motors
  • Bonding of miniature cameras
  • HDD assembly

 

Examples of potting/sealing applications:

  • Potting/sealing plugs, pin sealing
  • Curing of potting/sealing compound on smartcards
  • Chip encapsulation
  • LED potting/sealing
  • Potting/sealing of relays
  • Coil potting/sealing
  • Potting/sealing of PV modules
  • Potting/sealing of circuit boards
  • RFID
  • Potting/sealing of sensors
  • OLED encapsulation


Optical/optoelectronics industry

When it comes to active alignment, lens bonding or the potting/sealing of tiny camera modules in smartphones – tension-free curing of UV-reactive adhesives or potting/sealing compounds is needed. For fibre-optics bonding, on the other hand, you need high intensity and extremely short cycle times.

The powerful Hönle UV or UV LED point light sources, which can be adapted to suit your individual application, meet all these requirements.

Due to the greatly reduced IR content, UV LED point light sources do not require active air cooling. This results in other advantages: there is a marked reduction in the temperature load on the substrate, and the production environment is extremely low-noise.

From manual production via foot switch to small-series production in irradiation chambers right through to fully automated production lines with PLC control, Hönle UV technology has the ideal solution.

All Hönle UV and UV LED systems are precisely tailored to the UV-reactive adhesives made by Panacol, a Hönle Group company, ensuring a one-stop, process-reliable system solution.

Examples of bonding applications:

  • Lens bonding
  • Laser-optical systems
  • Bonding of glass fibres
  • Bonding of light guides
  • Active alignment
  • Photonics

 

Examples of potting/sealing applications:

  • Optical amplifiers
  • Photodetectors

 



Glass

As a material, glass usually has high transmission. This makes it ideal for bonding with the help of UV systems.

Our UV and UV LED systems are very frequently used in the production of glass furniture or when potting and sealing PV modules. Often, large areas need to be bonded or potted/sealed, requiring uniform irradiation of the entire adhesive surface. The particular challenge here is achieving low-tension curing. This is done by means of slow polymerisation of the adhesive. In other words, the homogeneity of the UV irradiation, rather than high intensity, is of primary importance in this application. Our UV line or flood lamps are used for bonding glass furniture.

 
UV-curing adhesives or UV potting/sealing compounds are also used in the jewellery and cosmetics industries. These applications typically involve the bonding or potting/sealing of small, filigree components, using UV or UV LED point source emitters to achieve reliable and complete curing within a short space of time.

UV blockers are sometimes integrated during the production of certain types of glass or laminated glass, for example those used in glass fronts for buildings, structural elements made from glass, lenses for (sun)glasses or acrylic glass. Even in such cases, UV bonding is often the right choice. Long-wave UV LED lamps are particularly effective in achieving reliable curing of the adhesive in these applications.

Adhesives manufactured by Panacol are optimally suited for use with Hönle UV/UV LED curing systems. The combination of these high-tech adhesive systems allows curing in a matter of seconds.

Examples of bonding applications:

  • Bonding of glass furniture
  • Jewellery
  • Cosmetics industry
  • Lenses for (sun)glasses
  • Glass building fronts / structural elements / glass construction
  • Wood-glass / metal-glass hybrid constructions

 

Examples of potting/sealing applications:

  • Potting/sealing of PV modules
  • Jewellery

 


 

Medical engineering

 

A typical bonding application in the field of medical engineering is needle bonding - the bonding of stainless steel needles or cannulas in glass or plastic syringes.

But UV and UV LED technology are also used to attach tube connections to hubs or catheters and for potting/sealing ECG electrodes.

High-intensity irradiation can be focused on needles by using conventional gas discharge technology and a special reflector geometry. This results in extremely short cycle times.

Hönle UV LED lamps are available in different wavelengths, allowing optimum adaptation both to the transmission characteristics of the materials to be joined and the absorption properties of the adhesive or potting/sealing compound. There is a wide range of LED radiators, point source emitters, flood and line lamps to choose from. Stepless power control and intelligent monitoring of the LEDs guarantee high process reliability. Cleanroom operation is possible using UV LED point source emitters or water-cooled flood and line systems.

In medical engineering applications, bonding has to meet the most exacting quality standards. High quantities with minimum cycle times are also a prerequisite. A reliable system solution is necessary in order to meet these requirements. The Dr. Hönle AG offers such solutions from a single source:

 
UV systems, conventional or with IR-free UV LEDs, in combination with UV-reactive adhesives manufactured by Panacol, a Hoenle Group company, and approved for medical engineering applications guarantee highly efficient and individual system solutions.

Examples of bonding applications:

  • Needle bonding
  • Catheters
  • Tube bonding

Examples of potting/sealing applications:

  • Endoscopes
  • Potting/sealing of ECG electrodes

 



Bonding plastics

One of the advantages of plastics is their low weight. To make full use of this advantage, attention is paid that no unnecessary weight is added when connecting plastic components. For this reason, bonding with adhesives has become the joining method of choice.

More and more mass-produced goods contain plastic. Here, manufacturers rely on a bonding technology which guarantees premium quality even at high production speeds - UV technology. Speed and reliability, but also the highest precision and compliance with health standards, are prerequisites in medical engineering, in particular during the manufacture of mass-produced medical equipment, for example when bonding needles in syringes.

The size of the areas of plastic to be bonded can vary greatly depending on the specific application. In medical engineering or the cosmetics industry, the areas to be bonded are usually small and can be cured with UV or UV LED point source emitters. For the bonding of large areas, for example caravan roofs, flood or line lamps are used. Uniform curing of the entire surface in order to achieve low-tension bonding plays a decisive role in the case of large areas.

The consumer electronics industry is an important area of application for our UV and UV LED curing systems. The advent of smartphones, tablet computers etc. has led to mass-production lines in which the individual components such as casings or covers are frequently bonded with the help of UV technology.

UV lamps are used for pre- and post-curing during the creation of 3D models, and Hönle also supplies the appropriate UV lamps for sewer renovation or dome coating.

Adhesives manufactured by Panacol are optimally suited for use with Hönle UV/UV LED curing systems. The combination of these high-tech adhesive systems allows curing in a matter of seconds.

Examples of bonding applications:

  • Bonding of casings
  • Bonding of caravan roofs
  • Bonding of smartphone covers
  • Cosmetics industry

Examples of potting/sealing applications:

  • Sewer renovation
  • Dome coating

 



Automotive applications

Potting/sealing and bonding with the aid of UV technology have long become indispensable processes in the automotive industry. They are a reliable solution for ever decreasing cycle times and increasing quality requirements. A wide range of UV systems is used, depending on the specific application. According to the adhesive or potting/sealing compound used, there is a choice between conventional technology with gas discharge lamps and IR-free UV LED technology.

Within seconds, high-intensity point source emitters can cure spot bonds on assemblies, sensors, matrix LED headlights and plugs as well as drying potting/sealing compounds, for example when sealing laser-welded seams. Large-area applications such as window and windscreen bonding, component assembly or mirror joining are performed with the aid of flood lamps.

Optimised reflector geometries or the uniform arrangement of LED flood lamps provide good homogeneity, ensuring that these areas are cured without tension and evenly. This ensures compliance with the most exacting quality standards, even for large areas.

High-intensity line lamps are used to cure adhesive beads applied, for example, when joining components for operating elements.

Depending on the heat-sensitivity of the components, conventional UV systems use IR filter and reflector technology to achieve a marked reduction in the temperature load.
From mobile production using hand-held lamps to small-series production in irradiation chambers right through to fully automated production lines with PLC control, Hönle UV technology has the ideal solution.

All Hönle UV and UV LED systems are precisely tailored to the UV-reactive adhesives made by Panacol, a Hönle Group company, ensuring a one-stop, process-reliable system solution.

Examples of bonding applications:

  • Bonding of windows and windscreens
  • Bonding of operating elements
  • Glass bonding
  • Component assembly

 

Examples of potting/sealing applications:

  • Sealing of laser-welded seams

 



White goods


Bonding with the help of UV technology also plays an increasingly important role in the production of white goods. It offers a reliable solution which meets new challenges such as long-term endurance tests, ensuring extremely low scrap rates and compliance with increasingly stringent quality requirements. A wide range of UV systems are used, depending on the specific application. According to the adhesive or potting/sealing compound used, there is a choice between conventional technology with gas discharge lamps and IR-free UV LED technology.

For example, adhesive dots on assemblies, pushbuttons, motors, sensors, plugs or trims can be cured in a matter of seconds using high-intensity point source emitters, and flood lamps can be used to bond larger areas, for example display screens, door handles or operating elements.

Optimised reflector geometries or the uniform arrangement of LED flood lamps provide good homogeneity, ensuring that these areas are cured without tension and evenly. This ensures compliance with the most exacting quality standards, even for large areas.

High-intensity line lamps are used to cure adhesive beads applied, for example, when bonding operating elements or cover panels.

Depending on the heat-sensitivity of the components, conventional UV systems use IR filter and reflector technology to achieve a marked reduction in the temperature load.

From mobile production using hand-held lamps to small-series production in irradiation chambers right through to fully automated production lines with PLC control, Hönle UV technology has the ideal solution.

All Hönle UV and UV LED systems are precisely tailored to the UV-reactive adhesives made by Panacol, a Hönle Group company, ensuring a one-stop, process-reliable system solution.

Example applications:

  • Bonding of cover panels
  • Bonding of operating elements
  • Display bonding