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.

Systems, apparatuses, and methods to seal a container are provided. An apparatus for securing a film to a container includes a body portion to house film and a sealing portion. The sealing portion includes a loading zone to receive a portion of film from the body portion and an aperture to receive a top portion of the container and the portion of the film therethrough to enable positioning within a sealing volume. A plurality of near-infrared light emitting diodes (NIR LEDs) face toward and at least partially surround the top portion of the container when positioned within the sealing volume. A controller is configured to receive sensor input from a sensor indicating that the top portion of the container is within the sealing volume and cause, in response thereto, activation of the plurality of NIR LEDs to secure the portion of the film to the top portion of the container.

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.

A simultaneous laser welding apparatus of a vehicle light comprising a placement support for a container body and a lenticular body of a vehicle light welded together at reciprocal perimeter profiles, a plurality of laser sources, a plurality of optical fibres associated with the laser sources at input ends for transmitting the light beams, a fibre-holder support device for blocking output ends of the optical fibres in predetermined positions, spaced apart by a pitch, a light guide provided with at least one seat which receives the light beams coming from the output ends of the optical fibres, to a light output wall which sends the light beams towards the welding interface. A single optical fibre is associated with each laser source.

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 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 portable table top welder for welding plastic material webs, the portable table top welder including a frame including a carrier housing and a support arm at which a welding device is arranged; at least one transport roller including a rotatable transport roller axle and at least one contact pressure roller that is rotatably supported at the carrier housing, wherein a weight is arranged at an eccentrical element which is rotatably connected at one side by a concentrically supported eccentrical element axle at the carrier housing and rotatably connected at another side by an eccentrically supported contact pressure roller axle at the contact pressure roller. The table top welder handles and transports easily and can be mounted on a table or on another carrier structure in a disengageable manner.

Welding apparatus (10; 30) having a safety feature comprising: two electrodes (11, 12; 21, 22), whereof at least one of said two electrodes is movably arranged in relation to the other electrode. The electrodes are in non-contact with each other and define a gap (13) in which an object (14) provided with an electrically non-conductive surface to be sealed may be inserted. The welding apparatus comprises an actuator (15; 25) configured to move at least one electrode when activated to squeeze the object, a detector (16; 26) configured to determine a clamping force when the inserted object (14) is squeezed between the electrodes, a distance sensor (17; 23) configured to measure the distance between the electrodes. There is also a conductance sensor (24) configured to measure the conductivity of an object located between the electrodes (11, 12; 21,22) when the object (14) is squeezed, and optionally a position sensor (19b) configured to detect the position of the object (14) inserted between the electrodes. The welding apparatus further comprises a processor configured to process the input from at least one of the detector (16; 26), the distance sensor (17; 23) and the conductance sensor (24) to provide an output that indicates if there is a blood bag tube inserted between electrodes, or if it is a foreign object.

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.

Provided among other things is a method of affixing a small, single chip to a plastic item, the chip having a top surface having length and width dimensions, and having a height, the method comprising: (1) vacuum adhering a top-oriented surface of the chip to a probe of outer dimensions comparable to or smaller than those of the length and width; (2) conveying heat to the chip via the probe such that a bottom-oriented surface of the chip is sufficiently hot to melt the plastic; (3) applying via the probe the chip to the plastic such that the chip embeds in the plastic; and (4) releasing the chip from the probe, wherein the largest of the length and width is about 500 microns or less, and height is no more than about the smallest of length and width.