Dissimilar Materials Welding
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Most RF and Impulse welding systems are only capable of welding two materials that have chemical compatibility and similar melt points. Dissimilar Materials Welding, however, allows for traditionally non-compatible materials to be joined with weld strengths that are as reliable as those of compatible materials.
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How it Works
Deposition of a material that is both compatible with the substrates, as well as the welding process is attached. This tie layer is then welded to both of the non-compatible substrates, thus tying the whole package together. An alternate technique involves making a cross-compatible material separately, then introducing it during the welding process. In many cases, solvents are used to prepare the welding surfaces.
Benefits
Biocompatibility requirements restrict the kinds of materials that can be used in regulated medical products. When the list of approvable materials does not include ones that are both compatible and have the desired properties, alternate forms of attachment are usually required (e.g. mechanical adhesive). These forms of attachment are usually more expensive and increase process risk. The Dissimilar Materials Welding process makes the joint stronger, more reliable, and less expensive.