APPLICATION

9 Induction to Plastic

Bonding Metal

Published bv the EPRl Center for Materials Fabrication Vol. 2, NO. 3, 1988 %I e

hrcmawd production. Using induction bonding, GTR can produce more parts than the competrtion with no additional labor requirements. With the hand-bending process, the cycle is approximately 1 part per minute. With induction bonding, GTR produces 2 parts in each 36-mond cycle GTR esti- mates that it produces 60% more than the competition with lover operating costs. In addition, the induction unit has caused no dawntime

of steps. Induction bonding eliminates the d gluing the part and cleaning off excess glue

Metal tabs are not needed on indlrction- resulting in a 50h metal savings. induction bonding, GTR avoided the

associated with gluing and the noise caused by sonic

Efmgy usmge. Productivity has increased at GTR without widding.

significantly raising electricity costs. The unit's 3-kW output power and 7"secOnd heating cycle result io minimum electricity usage

New product lines. Because the operation is simple and efficient, GTR anticipates additional market opportunities It has added another induction bonding unit for a similar screen application and is exploring the automotive market for attaching plastics to plastics. Plastics filled with graphte or metal filings can easily be induction bonded.

WhatDldIt" GTR's induction bonding unit cost about $20,000, including

the circulating water pump, coils, and the fixtures that hold the part during bonding. The fixtures and coils, custom-designed for each appkabon to guarantee accurate heating, cost from $5,000 to $15,000, depending on complexity. GTR's unit is dedicated to the screen operation but could be used for another operation by changing the fixtures, a 30-minute procedure that greatly increases the versatility of the unit.

The new system was installed and ready to go in l e s s than 1 hour. Workers learned the new system in about a day, and GTR reached opbmum production within a week.

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The Center for Materials Fabrication (CMF) wwld like to thank 4 herman of $gg$ '**!,:.a , Hellerbond Division, Columbus. Ohio, for valuable contributions made to thii issue. CMF is operated by Battelle's Columbus Division. Basic funding is I

ddopment on behalf of the United States electric utili industry. TechApplication Electric Power Research Institute, a nonprdii institute that conducts

efficient. electtic-based technologies in materials fabrication and related fields. is one of the ways the Center assists industry in implementing cost- and energy-

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If you have a success story you'd like to tell us about, or you'd like more information, c a l l or write us:

u w T m F m m r # u r ~ An EFW R&D Applications Center 505 King Awnue Columbus. Ohio 43201-2693 (614) 424-7742