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Infrared welding technology is increasingly favored by the market due to its unique advantages. A major advantage of this technique is that it uses a non-contact heating method to stop heating plastic workpieces. The surfaces of two parts to be welded can quickly condense under infrared light, and then be bonded together after pressing and cooling, achieving extremely high welding strength. The bonding strength between two components after infrared welding is much higher than that of other welding processes. The welds between components can achieve 100% air tightness, so there will be no air or liquid leakage. Infrared welded components will not exhibit weld slag or flash at the weld. Designs that cannot be completed using other welding processes can be arbitrarily completed here.

Therefore, infrared welding skills are particularly suitable for complex curved parts and large structural plastic parts, as well as welding most plastic components such as car lights, battery boxes, water bottles, instrument panels, airbag frames, and so on.

1. Introduction to Infrared

Infrared ray is one of the many invisible rays of the sun, which is an electromagnetic wave with a wavelength between microwave and visible light, ranging from 1 mm to 760 nm, and is divided into short waves (0.75 to 1.50 μ m) Medium wave (1.50 ～ 3.0 μ m) And long wave (3.0 to 1000 μ m) 3 zones.

2. Principles of infrared heating

Infrared light has a low frequency and can only penetrate the gaps between atoms and molecules of matter, speeding up the vibration and widening the spacing of atoms and molecules, thereby increasing heating motion energy. From a macro perspective, matter melts and vaporizes when heated, but the essence of matter has not changed. This is the principle of infrared heating.

3. Principles of infrared welding

Infrared welding uses a non-contact radiation type heating method, using an energy controlled infrared generator to weld plastic parts. Infrared welding is a generator based on short-wave infrared light, characterized by very fast start-up and closure. After quickly moving to the surface of the plastic part to be heated, it takes only a few tens of seconds to quickly plasticize the surface of the workpiece to the set depth. Generally speaking, the plasticizing time can only take up to 12 seconds, which also depends on the characteristics of the material of the parts to be welded.

When the product is infrared welded, the infrared radiator is inserted between two plastic parts. When the workpiece approaches the infrared generator, the parts begin to melt. After reaching the preset heating time, the welding ribs are fully fused, and the infrared generator quickly exits. Subsequently, the left and right workpieces are merged together. When a certain welding time and depth are reached, the welding process is completed.

Benefits of infrared radiators:

(1) It can achieve full power output in 1-3 seconds, which is stable and greatly saves energy consumption;

(2) The control temperature can be set in zones to achieve accurate and controlled heating and welding processes;

(3) Non contact heating ensures that materials do not remain in the hot distance, improving production efficiency;

(4) The component welds can achieve 100% air tightness without causing air or liquid leakage;

(5) A 3D geometric radiator can be made based on the heated material to meet different needs, and targeted heating can be performed on the shapes of the frame, edges, and edges;

Selection of infrared radiators

The surface temperature of the shortwave radiator can reach 1800~2200 ℃, which can be used for welding plastic parts. Due to its low absorption, thermal radiation can penetrate deeper into the interior of the material, ensuring uniform heating. At the same time, using short-wave radiators, the speed of reaching the material surface decomposition temperature will also be slower, thereby avoiding thermal damage. The surface temperature of medium wave radiators is between 800 and 950 ℃. Since most of the thermal radiation is absorbed by the most surface materials, medium wave radiators are mainly used to heat surface materials, such as the welding of plastic films and the drying of paints.

Therefore, it is very necessary to select suitable infrared radiators for different materials and processes. The selection of the wavelength of the radiator should be consistent with the absorption spectrum of the material, which will allow for faster heating of the product without any additional environment and equipment heating. Choosing a suitable infrared radiator can greatly reduce the energy consumption of equipment in a factory.