Technical consultation is free
No adhesive or screws needed. Our proprietary instantaneous heating and cooling method
delivers a clean finish with no stringing, burn, or flash.
Start with a free demonstration.
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PROBLEM
SOLUTION
The IMPULSE WELDER is heat staking system with instantaneous heating and cooling which is safe, stable and energy-saving. It is also environmental friendly in terms of easy recycle of parts. The method is patented. With no adhesive or screws, the process stays clean. It solves on-site challenges while reducing environmental impact at the same time.
SOLUTION.1
SOLUTION.2
SOLUTION.3
The IMPULSE WELDER uses instantaneous heating and cooling to join parts cleanly, quickly, and reliably. Apply electrical current to heat tip and heat tip is heated up by Joule heat. After melting and forming thermoplastic, cool air blows solidify plastic. Many points can be staked simultaneously. Even 100 points in the same time as 1 point.(Time may vary with size of heat tip) The finish has no stringing or burn. Quality improves without reducing line efficiency.
| Laser welding | High-frequency welding | Ultrasonic welding | Heat staking (IMPULSE WELDER) |
|
|---|---|---|---|---|
| Welding principle | Absorption of laser light | High-frequency dielectric heating | Frictional heat from vibration | Joule heat of the heat tip |
| Effect on the product | Effect of laser light | Effect of electromagnetic waves | Effect of vibration | Extremely low |
| Applicable materials | A transmissive material and an absorptive material must be paired (color is limited) | Limited to certain dielectrics such as PVC and nylon | Works with many plastics, but compatibility with the horn varies | Proven with many thermoplastics. Glass fiber content up to about 30% (guideline) |
| Stability of quality | Small differences in environment or material color easily cause burn or incomplete welding | Easily affected by the electrical properties of the material, and hard to adjust | Heat comes from friction, so temperature control is not possible and variation is likely | Temperature control keeps quality constant (high repeatability) |
| Best applications | Fine parts where appearance matters | Film and sheet | Simple shapes, high-speed mass production | Precision circuit boards, multi-point welding, medical devices, etc. |
USE CASE
The IMPULSE WELDER is already building a record in a range of applications. It can accommodate all kinds of needs depending on how it is used.
It flexibly handles combinations of different materials, such as plastic + plastic, plastic + metal, and plastic + nonwoven fabric.
Click to see sample photo
Most common usage. Different "a" and "b" material can be staked. Low pressure leaves little impact on the surface.
【Automotive】Tail lamp, high-mounted lamps trunk side, side molding, dashboard (meter panel, shift bar, steering wheel cover), seat peripherals
【Electric】Bath controller, digital electronics (circuit board assy)
【Precision parts】Camera lens parts, electronic parts
Deeply melting "a" to fuse with "b". Good sealing result achieved.
【Automotive】Door trim, deck side trim, pillars
【Electric】Switch panel
Staking without making holes in metal mesh.
【Automotive】Cowl louver mesh
【Other】Mesh filter
Bond by plastic melted into fibrous structure and solidified.
【Automotive】Bond nonwoven fabric to inside of door trim or pillars (PET and Thinsulate can be used)
Stake by heating directly from the top of the filter.
For water-resistant breathable material ABS(Antilock brakes), Motor part, electronics part
Embed flanged nut and seal hole.
Electronic device case
Hot press insert nut.
【Automotive】Intake manifold, air filter
【Electric】Audio product
Flat head (even surface) staking at concave section or chamfered section.
【ICT】Keyboard assy (back side), Battery terminal assy
Seal air hole of blow moldings.
Hole of blow moldings, relay case, electrode holes of FFS
Rim swaging to lock parts in position.
Camera lens, metal part lock
Applicable plastics: ABS, PP, PS, PE, PC, POM, PMMA, PBT, ABS/PC, PPS, PPA, PET, PA etc
Applicable for plastic with glass-fiber.(need detailed study) The above is based on our welding track record to date.
If you would like to check whether it works with your parts, including applicable materials and welding patterns,
please feel free to contact us. Free demonstrations are available.
Here is how the Impulse Welder controls the conditions of welding.
The roles of each process are described below.
There is no stringing, burn, or flash because heating and cooling are controlled precisely.
The IMPULSE WELDER offers two control methods to achieve optimal welding conditions for each material and part.
Phase (power control) method: heat tip temperature profile
Heating is possible both for heating and for welding. Input by timer is possible individually for heating, welding, and cooling. Phase control level (heating) setting can be used to change the angle of temperature rise. Also, phase control level (welding) can be used to maintain a stable temperature for the welding time. The roles of the processes are the same as in the timer control method.
The front or rear of each half-cycle of the AC waveform is cut to control the effective voltage applied to the load and adjust heater power.
DC method: heat tip temperature profile
Our proprietary product: DC-IPW
1. Improved quality stability
2. Easier maintenance
3. Greener and more energy-efficient
| Transformer timer control | New DC-DC timer control | Transformer temperature control | |
|---|---|---|---|
| Heating method | Heating timer control, AC transformer | Heating timer control, DC-DC converter | Temperature PID control, AC transformer |
| Power supply | AC transformer | DC-DC converter | AC transformer |
| Features | The simplest and lowest-cost structure. Operated by timer settings only. A phase-control type is also available. | Voltage is held constant, so it resists power-supply fluctuation. Among timer types, it is highly stable. | Feedback control manages temperature directly. It prevents over-melting and insufficient staking. |
| Suitable applications | Lower-cost products that do not need high precision, and thermoplastic parts that are easy to weld. | Great cost advantage for multi-point welding. Assembly of electronic parts that need moderate precision. | High-precision uses such as medical devices, automotive parts, and staking of fine terminals. |
+ hand grip
+ [Slide unit] + lever press, robot.
+ [Slide unit] + Built in the equipment.
See the catalog for specifications.
Phase power control enables stable heating and condition setting. Options include AC100V / AC200V power and 1 or 2 welding points.
A multi-function machine that offers timer control in addition to temperature setting and management. AC100V / AC200V power is available as an option.
Large numbers of points can be welded simultaneously in a short time and with high reliability. Make to order, the machines can be built to your specifications. Please feel free to contact us.
See product specifications in the catalog.
Can I check whether it works with our materials and parts? 
We offer free demonstrations. Bring your actual parts and we can run a welding test. Please feel free to contact us.
Are there plastics you cannot weld?
Thermosetting plastics cannot be welded. In principle, any thermoplastic can be handled, but we decline PVC because it generates toxic gas. We offer free demonstrations. Bring your actual parts and we can run a welding test. Please feel free to contact us.
Do you support multi-point welding?
Many points can be staked simultaneously. Even 100 points in the same time as 1 point.(Time may vary with size of heat tip) As long as the heat tips can be physically arranged, all welding points can be welded simultaneously. Welding from multiple directions is also possible, so please consult us.
How often do heat tips need replacing?
It depends on usage. As a guide, standard heat tips (IHT-X series) last about 200,000 shots, and special machined heat tips (IHT-S series) about 300,000 shots. Some customers have used them even longer.
Can it be built into an existing line?
Yes. It can be built in the equipment. We design and install systems to suit your site, taking into account process balance with upstream and downstream processes and safety standards. Details are worked out through a series of meetings. Please feel free to tell us about your current line issues and the space you are considering.
How much does it cost to introduce?
Since we design each machine to your specifications, costs vary. Please contact our sales department via the inquiry form.
What is the process from demonstration to installation?
The standard process is: Inquiry → Technical introduction (demonstration) → Confirmation of specific themes and requirements → Prototyping → Adoption review → Specification meeting → Quotation → Order → Design start → Design review → Production after approval → Factory acceptance test at our facility → On-site installation → Post-delivery follow-up.
