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Portable Lighting Manufacturer

A leading manufacturer of premium portable lighting was looking to ruggedize its safety flashlights, which are used by firefighters, police officers, and military troops in the field. In their search for a fast curing sealant with excellent adhesion properties, they turned to the Dymax Application Engineering team for help.

Challenge

Finding a strong fast curing adhesive to ruggedize the lens and reflector housing.

When the customer developed some new flashlights, they were looking for a way to ruggedize the lens and reflector housings by applying a sealant to bond the subassembly together. Their engineers needed the flashlights to withstand rough handling and extreme conditions in the field, and to work in a wide range of environments, such as search-and-rescue or life-threatening situations.

Solution

Multi-Cure® 621-T has excellent adhesion properties while curing in seconds. Dymax 2000-EC flood lamp provided the best curing solution for the 8" x 8" curing area.

Dymax application engineers, always looking for the next challenge, worked closely with the customer’s team to come up with an innovative solution. After researching and testing our customer’s parts, Multi-Cure® 621-T was recommended to bond the glass lens to the reflector housing. The decision was made based on 621-T’s ability to adhere dissimilar materials, its fast cure, and excellent adhesion properties. To bond, the subassembly, the lens, and reflector housing were placed into a small rotary system underneath a dispensing valve and 621-T was applied in a uniform bead into the bond line. Our application engineers suggested using a Dymax 2000-EC flood lamp to cure parts post-assembly because it offered a large 8” x 8” curing area, as well as high-intensity curing in 5-30 seconds. The parts were assembled and then exposed to UV/visible light under the Dymax flood lamp. Rapid curing allowed the bonded parts to swiftly move onto the next step in the manufacturing process with virtually no down/wait time.

Results

A very happy customer that reduced its costs and increased its output because of the Dymax system's solution.

Our customer was impressed with the technical expertise of our AE team. They were also very satisfied with Multi-Cure® 621-T and with how our 2000-EC Flood Lamp enhanced their process by curing a large area in just a few seconds. Our solution enabled faster processing, greater output, and lower processing costs

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