A method for fusing thermoplastic composite structures includes placing a substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one insulation layer over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and applying a vacuum bag to at least partly enclose the skin and the substructure. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

Described is a heated gaseous welder system and associated methods of welding plastic with the heated gaseous welder system. The heated gaseous welder system includes a welding tool and a welder control unit. The welder control unit includes a gaseous control system and a heater control system. The gaseous control system is configured to selectively supply a gas to the welding tool and control at least one characteristic of the gas supplied to the welding tool. The heater control system is configured to selectively control power supplied to the welding tool.

A packaging machine including a hot plate assembly adapted to fuse a length of heat-sensitive film wrapped around a package. A controller is adapted to calculate a time period the heating element is energized to fuse the length of heat-sensitive film wrapped around the package based on an initial temperature of the heating element. A hot plate status indicator is adapted to indicate at least to different statuses of operation of the packaging machine.

A method for sensing intensity of laser light in a simultaneous laser welding system includes placing a smart part in a weld area. The smart part includes at least a laser light intensity sensor for sensing laser light directed at it. Laser light intensity is sensed by the laser light intensity sensor of the smart part which provides an output signal indicative thereof to a controller.

A welder for joining two polymeric sheets together using a wedged heating element allows for a heating profile on opposite faces of the heating element to be varied by controlling where each of the polymeric sheets contacts the corresponding face.

Embodiments herein include a system for joining components. The system can include a rotating base platform, a plurality of receptacles mounted to the base platform, and a rotating sonotrode platform. A plurality of sonotrodes are mounted to the sonotrode platform. Each sonotrode can correspond to a receptacle. Each sonotrode can move in a reciprocating motion between a release position distant from a corresponding receptacle and a compressing position proximal to the corresponding receptacle. The compressing position occurs at a first angular position of the sonotrode platform. Each sonotrode is energized at the compressing position.

A method of welding at least two plastic components together is disclosed. The two plastic components are welded together at respective joining surfaces. The method comprises directing at least one infrared (IR) laser beam along the joining surfaces of the at least two plastic components. The IR laser beam heats the joining surfaces of the at least two plastic components to a welding temperature. The method also includes clamping the at least two plastic components together at the joining surfaces to create a weld.

A method and apparatus for sealing a plastic enclosure is provided. The apparatus includes a handle including elements pivotally coupled together at a first end. The apparatus also includes a heating element positioned along an inner surface of an element and connected to a power source where a longitudinal axis of the heating element is oriented parallel with a longitudinal axis of the element. Plastic material including first and second plastic layers is positioned at an interface between the second elements. Upon pivoting the first elements from an open position to a closed position the heating element increases a temperature at the interface to melt the plastic material and form a seal between the first and second plastic layers.

A joining material for laser welding, a laser welding method using the same, and a laser joined body using the laser welding method. The joining material includes a polymer matrix and a needle-shaped inorganic filler. The polymer matrix includes a polypropylene resin having a melt index of 80 g/10 min or more to 95 g/10 min or less as measured at a temperature of 230° C. and a load of 2.16 kg, and the needle-shaped organic filler has an aspect ratio of 10:1 to 20:1.

A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. The heated portion may contact the faying surfaces and melt them through conduction, or may be suspended between them and melt them through radiation and convection.