The invention and use of infrared plastic welding machines (NICLE, a US research and development company) has developed an advanced method for infrared penetration (TTIR) welding of sensitive plastic parts. The emerging company's P-wave TTIR device is capable of producing multi-color (multi-wavelength) infrared energy instead of the monochromatic (single-wavelength) infrared energy used in laser welding.

Mr. Masnori Kubota, President of NICLE, stated that P-waves provide a new way to weld transparent, translucent and colored parts and films, and that it can weld a wide range of engineering plastics. Like laser welding, P-waves focus infrared energy on the area between the infrared transparency and the infrared absorbing portion, causing the interface to partially melt. This melting, combined with the applied pressure, bonds the parts together. However, Kubota said that P-wave is a more precise, more tolerant and less expensive welding method than infrared laser welding.

KRA believes that infrared plastic welding machines outperform infrared laser welding in welding electronic, automotive and medical components, films used in fuel cells and bio-liquid bags, and certain composite parts. Surface defects (ablation) of parts are greatly reduced. It is said that the use of KRA technology in conjunction with the corresponding wavelength transducers allows for precise guidance of infrared energy so that high temperature polymers such as fluoropolymers and polyetheretherketone (PEEK) are the first to be used. The TTIR welding has become obedient.



How P waves work

John Long, chief technology officer of KRA, said the power of the P-wave devices offered is 300 and 500W. The system includes an infrared lamp (halogen, helium or metal halide) as well as a patented optical focusing device and KRA's proprietary wavelength transducer. The device produces an unconventional solder joint with a diameter of approximately 5 mm, and a robotic raster scanner can be used to expand the weld area.

KRA's infrared lamps and optics produce a filtered, bandwidth-conducting, cone-shaped beam that precisely and deeply illuminates the infrared energy in the solder interface area, making local precision soldering possible. The patented optical component focuses the infrared beam to such an extent that it can penetrate deeper into the plastic part than the laser energy, while reducing damage to the surface of the part.

Mr. Long said that in most cases, P-wave soldering is most effective with wavelength transducers. The transducer is a plastic film, strip or die cutting device made of an infrared absorbing material that is placed on or over the part being welded.

The transducer focuses the infrared beam energy onto the soldering interface like a lens, increasing the energy flow density by 300%, thereby accelerating the melting rate of the soldered area. The transducer can be designed according to the shape of the welded joint, which will facilitate the welding of 2D or 3D joints. This equipment can weld films, sheets, cloths, sheets, tubes and molded parts.

Wavelength transducers can weld natural (infrared transparent) materials into bags and containers, such as polyethylene blood and biological fluid bags. These flexible containers can replace the PVC bags currently in use, thereby avoiding the risk of toxic gases when incinerating these vinyl bags. The P-wave device can also weld non-woven bags and medical wraps made with DuPont's Tyvek film. Another use is in fluoropolymer bags used in biological and environmental sampling procedures.