Polymer weld strength predictions using a thermal and polymer chain diffusion analysis

A new simplified model for strength prediction of welded polymer‐polymer interfaces is proposed. Two schools of thought exist for strength prediction of polymer‐polymer interfaces: microscopic analysis of polymer chain behavior, and macroscopic analysis of bulk polymer properties during welding. The microscopic analysis is based on De Gennes' reptation theory for macromolecules (1), and has been described extensively by both analytical and empirical techniques. Reptation models are based on constant temperature interfaces, which are not found in any actual welding process. Conventional macroscopic analyses of welding empirically relate strength to important thermal process parameters, such as power density and heating time, but do not address the behavior of the polymer chains. Little interaction exists between these two schools of thought. This study seeks to combine these two areas, using reptation theory to explain the polymer chain interactions on a macromolecular level, and relate the interface thermal signature to strength prediction. The result of the new model is a method for strength prediction that takes into account fundamental materials properties as well as the engineering conditions imposed in a realistic welding process to predict weld strength. The model is adapted to run for similar conditions as two separate empirical endeavors. The results show that the model is effective in predicting overall trends, which emphasizes the importance of examining heat transfer effects in any polymer welding process.