Reduced weight, space, and cost in headliner assembly

 

Through-transmission IR welding

Innovative through-transmission infrared welding in a compact package that reduces weight, space, and cost of a headliner assembly. InfraWeld® uses zero consumables and can change the way you manufacture headliner assemblies.

The InfraWeld Process

Reflective surfaces focus infrared energy from an IR lamp through a top component and into a lower component causing it to heat up. An integrated seal allows for air pressure to force the two softened components together for welding.

Clamp

The module extends and clamps the components together creating an airtight seal around the weld area.

Heat

Reflective surfaces inside the module focus the IR energy from a technical-grade halogen lamp and direct it toward the weld interface. The energy transmits through the top part and is absorbed by the surface of the lower part, commonly referred to as through-transmission infrared (TTIR).

Bond

Air pressure inside the module forces the two softened components into each other. After the lamp is turned off, the module continues to clamp and apply pressure to the weld allowing the materials to bond.

Cool

The module retracts slightly, and cooling air is blown over the weld. The result is a robust joint that is stronger than the parent strength of the headliner itself. Typical cycle times are 10-25 seconds.

For a more ‘in-depth’ description of the InfraWeld technology, please see the InfraWeld, Through-Beam Welding at the IR Spectrum white paper.

InfraWeld Overview

The InfraWeld process uses infrared energy to bond a transparent or translucent material to a compatible opaque material with through-transmission welding. This process is different than laser welding. Lasers produce energy intensely focused on a fine point. Conversely, the InfraWeld process heats a focal area with less intense energy making it a safe, efficient, and versatile technology. Laser welding applications are typically full perimeter welds for hermetic seal specified assemblies. InfraWeld is better-suited for spot-welding applications such as welding HIC and other components to automotive headliners.

Reduces Weight

The InfraWeld process uses zero consumables so assemblies are lighter than those that are glued together. Depending on the application, InfraWeld can save more than a pound of glue!

Reduces Space

Without the thickness of glue to account for, headliners assembled with InfraWeld reduce the stack height by 1 mm.

Reduces Cost

Headliners assembled with InfraWeld are lower cost. Some applications are $3 cheaper per part!

  • Optimized for a small area of thin material for welding
  • Focused IR energy transmits through top material and is absorbed by bottom material
  • Tested to work with several materials including: PP, ABS, PU, PC/ABS, PC, PMMA, and more
  • 100 W tungsten halogen lamp
  • 32 mm diameter module
  • 25 mm diameter weld area (approximately)
  • 136 mm long module

Learn more about InfraWeld

 

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