# US 11,110,665 B2 · System and method for direct infrared (IR) laser welding

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- Number: US 11,110,665 B2
- Document ID: US11110665B2
- Status: Granted
- Kind: B2
- Application number: 15/438,004
- Filed: 2017-02-21
- Published: 2017-06-08
- Granted: 2021-09-07
- Earliest claimed: 2014-03-28
- Assignees: Sogefi Engine Systems USA, Inc.
- Applicants: Sogefi Engine Systems USA, Inc.
- Inventors: Stephen Thompson; Yannis Maudet; Nuno Demetrio Soeiro
- Web page: https://patentgrep.com/patent/US11110665B2

## CPC

- B29C 65/1612: {Infrared [IR] radiation, e.g. by infrared lasers}
- B29C 65/1632: {direct heating the surfaces to be joined}
- B29C 65/1661: {scanning repeatedly, e.g. quasi-simultaneous laser welding}
- B29C 65/1667: {at the same time, i.e. simultaneous laser welding}
- B29C 65/1683: {coated on the article}
- B29C 66/1312: {Single flange to flange joints, the parts to be joined being rigid (the parts to be joined being flexible B29C66/133)}
- B29C 66/54: {Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles}
- B29C 66/73921: {characterised by the materials of both parts being thermoplastics}
- B29C 66/934: {by controlling or regulating the speed}
- B29C 66/944: {by controlling or regulating the time}
- B29C 66/95: {by measuring or controlling specific variables not covered by groups B29C66/91 - B29C66/94}
- B32B 37/0046: {characterised by constructional aspects of the apparatus}
- B32B 37/04: characterised by the partial melting of at least one layer
- B32B 37/06: characterised by the heating method
- B32B 37/182: {one or more of the layers being plastic}
- B32B 37/24: with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate (B32B37/15 takes precedence)
- B32B 38/0008: {Electrical discharge treatment, e.g. corona, plasma treatment; wave energy or particle radiation (heat treatment B32B38/0036)}
- B32B 38/18: Handling of layers or the laminate
- B29C 65/1677: {making use of an absorber or impact modifier}
- B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)}
- B29C 66/712: {the composition of one of the parts to be joined being different from the composition of the other part}
- B29C 66/863: {Robotised, e.g. mounted on a robot arm}
- B29C 66/9161: {by controlling or regulating the heat or the thermal flux, i.e. the heat flux}
- B29C 66/919: {characterised by specific temperature, heat or thermal flux values or ranges (specific electrical resistance values B29C66/81262)}
- B29C 66/929: {characterized by specific pressure, force, mechanical power or displacement values or ranges}
- B29C 66/939: {characterised by specific speed values or ranges}
- B29K 2101/12: Thermoplastic materials
- B29L 2031/7492: {Intake manifold}
- B32B 2037/243: {Coating}
- B32B 2605/08: Cars
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

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.

## Claims

### Claim 1

A method of welding at least two plastic components together, wherein the at least two plastic components are welded together at respective joining surfaces, wherein the at least two plastic components have differing geometries relative to each other, the method comprising:
repeatedly scanning a first infrared (IR) laser beam across one of the joining surfaces and a second IR laser beam across another of the joining surfaces, of the at least two plastic components, wherein the IR laser beams heat each of the joining surfaces of the at least two plastic components to a welding temperature at about the same time;
adjusting at least one welding parameter of at least one of the first and the second IR laser beams to accommodate the differing geometries of the at least two plastic components; and
clamping the at least two plastic components together at the joining surfaces to create a weld;
wherein the at least one welding parameter includes at least one of a travel speed of at least one of the first and the second IR laser beams, a scanning frequency of at least one of the first and the second IR laser beams, or a duration at which at least one of the first and the second IR laser beams heats the at least one of the plastic components; and
wherein the repeatedly scanning comprises repeatedly scanning at least one of the first and the second IR laser beams across the joining surface areas at a rate of about ten to about two hundred passes per second.

### Claim 2 (depends on 1)

The method as recited in claim 1, further comprising positioning ribs along the joining surface areas to accelerate the melting of the joining surface areas.

### Claim 3 (depends on 1)

The method as recited in claim 1, comprising controlling a specific amount of energy per surface area created along the joining surface areas of the at least two plastic components.

### Claim 4 (depends on 1)

The method as recited in claim 1, comprising rotating both the at least two plastic components by about ninety degrees before clamping.

### Claim 5 (depends on 1)

The method as recited in claim 1, comprising translating at least one of the at least two plastic components in a linear direction before clamping such that a first joining surface area of a first plastic component generally opposes a second joining surface area of a second plastic component.

### Claim 6 (depends on 1)

The method as recited in claim 1, comprising applying a coating to the joining surface areas of the at least two plastic components.

### Claim 7 (depends on 1)

The method as recited in claim 1, comprising adding a colorant to a material the at least two plastic components are constructed of, and wherein the colorant absorbs energy emitted by at least one of the first and the second IR laser beams.

### Claim 8 (depends on 1)

The method as recited in claim 1, wherein each of the IR laser beams includes a wavelength of least about 2000 nm.

### Claim 9 (depends on 1)

The method as recited in claim 1, wherein at least one of the first and the second IR laser beams are generated by at least one IR laser beam source, and wherein the at least one IR laser beam source is one of a diode laser, a solid-state laser, and a gas laser.

### Claim 10 (depends on 1)

The method as recited in claim 1, wherein the at least one welding parameter includes a travel speed of at least one of the first and the second IR laser beams.

### Claim 11 (depends on 1)

The method as recited in claim 1, wherein the at least one welding parameter includes a scanning frequency of at least one of the first and the second IR laser beams.

### Claim 12 (depends on 1)

The method as recited in claim 1, wherein the at least one welding parameter includes a duration at which at least one of the first and the second IR laser beams heats the at least one of the plastic components.