InfraWeld Replaces Glue in Headliner Assemblies

 Headliner manufacturers have searched high and low for an assembly method that would eliminate the costly and troublesome process of the application of hot-melt adhesive to retain H.I.C. (Federal Motor Vehicle Safety Standard Head Impact Criteria) components, wiring harnesses, and other items that populate the 'B' surface of these critical interior panels.

Extol is pleased to announce that after a 1-1/2 year development effort the InfraWeld® process - a method derived from our popular InfraStake® product, has proven successful in complete Headliner performance testing and we were recently awarded our first production-intent, assembly equipment program for the 2008, Ford F-150 platform...how cool is that?!

Our partners in this exciting new assembly method are the Oakwood Group - Michigan based manufacturer of SafetyPlastic®, and TrimQuest - also Michigan based, and a premier Headliner and Overhead Systems manufacturer.

The advantages to eliminating 'glue' from a manufacturing perspective are numerous. Typical issues presented with this dated bonding method include, but are definitely not limited to: the adhesive must be heated - continually, and pumped through a dispensing device; simply put - the adhesive is a consumable, and not exactly 'Green'; a burn hazard exists during manual application and service; continual maintenance challenges persist, and unless automated the application can be, well...a stringy, snotty mess.

In addition to the elimination of these manufacturing issues, a significant weight reduction can be realized in the finished product...this a continual goal and challenge posed from the auto makers. 

As InfraWeld is indeed a welding process, compatible materials must exist at the joint interface to achieve a true intermixed weld. Some non-compatible materials can be 'bonded' with InfraWeld but strength and environmental cycling performance may reveal less than desirable results.

The SafetyPlastic components pictured on this page are thermoformed Polypropylene products, the Headliner surface is an Azdel® composite - also a PP product in part (pictures are of pre-production parts).

Similar to our InfraStake product, the InfraWeld process utilizes a very defined application of infrared energy which produces heat sufficient to melt the subject plastic. In the case of InfraWeld the light energy is projected as more of a beam than the defined focal point or zone that is within the InfraStake module.

This infrared light beam projected from the InfraWeld module passes through the HIC component heating both materials at the interface.

Unlike the InfraStake product that incorporates an integrated punch to form a semi-molten stud, InfraWeld relies on a tightly controlled positive air pressure to achieve the force required to execute strong and consistent spot-welds while preventing 'A'-surface marking...a very big deal!

We really try hard here at Extol to find a better way in the business of plastics-joining; 'a new thing' isn't good enough, we understand that new technology must really be better...not just new! We get terms like robust, efficient, cycle-time, and of course, cost justified. 

InfraWeld is proof...can we be of assistance?