IR End Cap Welding System

At Thermal Innovations Corp., we are able to bring together state-of-the-art technology and quality engineering to develop custom thermal processing systems. Whether building a cost-effective modular system or designing a from the ground up custom project, we can always provide a comprehensive solution that captures every nuanced requirement of your manufacturing or treating process. Furthermore, our expertise in multiple types of heating systems ensures that we are best suited to delivering performance and efficiency in one package.

We recently assisted a filter manufacturer primarily working with plastic end cap materials. Their manufacturing workflow requires attaching plastic endcaps to pleated paper filter media with a strong, durable seal. Since welding heat must be localized to the cap itself, the customer was not able to find an off-the-shelf solution for improving weld quality and cycle time. They came to us directly because of our prior work on developing custom systems.

(Click on thumbnail to enlarge)

Filter Cartridge and End Cap Prior to IR Welding
Filter Cartridge and End Cap Prior to IR Welding
IR End Cap Heating Prior to Welding
IR End Cap Heating Prior to Welding
Completed IR Welded Filter Assembly
Completed IR Welded Filter Assembly

Based on their product specifications and application directives, we designed and built a custom plastic welder for their filter product. This system, capable of capping two filters at once, clamps the filter and end cap and uses a non-contact electric infrared heater that applies heat to the specific dimensions and areas that need to be welded. Largely automated, our custom system requires no interaction beyond loading and unloading of filter units. Our system provided a stronger, and more consistent weld while still significantly improving cycle times and even personnel safety.

We continue to deliver smartly engineered, effective, and cost-conscious solutions for thermal treatment processes and procedures. Whether you’re a small-scale customer looking for a great way to upgrade production, or a heavy industry facility in desperate need of faster, more consistent thermal treatments, we will be able to meet your needs exactly.

For more information about our capabilities, portfolio of work or current technology offerings, feel free to contact us directly. end caps.

Additional Information

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