Heating Element Welding

Operational principle:

  1. The workpieces, which can be connected, are clamped in a holding tool.
  2. Between the accordingly prepared joining areas, the heating element gets retracted.
    Via contact or radiant heat takes place a plasticizing of the welding zone.
  3. According to sufficient plasticizing the workpieces are separated from the heating element and the heating element goes back into the starting position.
  4. By the defined adding of the plastifized workpieces, an unsolvable, gas and waterproof welding joint is created.
operational principle of heating-element-welding
manuelles Schweißen mit Heizelement
Manual welding with heating element, as example:
Welding parameter for pipings of PP.

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Application references:

The joining areas of the welded parts are to be designed according to the requirement of the welded joint. The exact and reproducible adherence to the welding parameters guarantees an optimum at quality of the welding seam for this connection procedure.

Contrary to ohter welding methods spatially formed and complicated joining areas can be reliably connected.
There are no limitations of dimensions for the parts, which are to be welded..

partly automated welding
Partly automated welding with heating element in production line.

Compared with other welding methods the thermal welding is the most reliable and safest welding method for thermoplastic plastic parts due to the direct energy introduction application and the temporally streched adding process.
For very large and complicated joining areas, with which the building of a heating element would be very complex, also heatin welding rods are used.

Satisfied materials:

PMMA; PP; PVC; PBT; PE; PS; ABS; POM; PA6; PA12

PMMA with ABS; PMMA with PVC; PMMA with PS good; PVC with ABS and HDPE with PP limited

Samples of application for heating element welding:

Lights, battery manufacturing, tail lamps for cars, connecting tube bodies of all kinds, beros, sensors, various cases, interior for domestic appliances, construction units of the medical technology, squirting and shaped parts of Polyolefins, parts with wide connections.

Informationen zum Heizelement-Schweißen Informations about heating-element-welding as pdf...

For example:

Approximate values for the butt welding with heating elements of pipings of PP are arranged in the following table.
(source: Instruction card DVS 2207, Teil 11, April 1985)

  Wall thickness / mm 2 ... 3,9 4,3 ... 6,9 7,0 ... 11,4 12,2 ... 18,2 20,1 ... 25,5
1. Asapting up to bulge height / mm 0,5 0,5 1,0 1,0 1,5
2. Heating up / s 30 ... 65 65 ... 115 115 ... 180 180 ... 290 290 ... 330
3. Changing over / s 4 5 6 8 10
4. Cooling down / min 4 ... 6 6 ... 12 12 ... 20 20 ... 30 30 ... 40

 

Funktionsprinzip des Schweißverfahrens

Explanation:

Adjust the heating element (in picture: red) up to 190°C (thicker materials) to 210°C (thinner materials). Joining areas (jointing part in picture blue) must be flat and freely from foreign matter and oxide coating.

Welding procedure:

  1. Adapting time under p = 0,10 N/mm² to at least indicated bulge height is reached.
  2. Warm up period under p = approx. 0,01 N/mm²
  3. Changing over time
  4. Cooling time under p = 0,10 N/mm² (total time up to the sufficient cooling)