System and method for direct infrared (ir) laser welding

Abstract

A system for welding at least two plastic components together is disclosed, where the plastic components are welded together at respective joining surfaces. The system includes at least one infrared (IR) laser beam source positioned relative to the at least two plastic components and a control module. The IR laser beam source generates an IR laser beam. The control module is in operative communication with the at least one IR laser beam source. The control module includes control logic for controlling the at least one IR laser beam source to heat the joining surfaces of the at least two plastic components to a welding temperature.

What is claimed is: 
     
         1 . A system for welding at least two plastic components together, wherein the at least two plastic components are welded together at respective joining surfaces, the system comprising:
 at least one infrared (IR) laser beam source positioned relative to the at least two plastic components, wherein the at least one IR laser beam source generates an IR laser beam; and   a control module in operative communication with the at least one IR laser beam source, the control module including control logic for controlling the at least one IR laser beam source to heat the joining surfaces of the at least two plastic components to a welding temperature.   
     
     
         2 . The system as recited in  claim 1 , wherein the control module includes control logic for adjusting at least one welding parameter of the IR laser beam. 
     
     
         3 . The system as recited in  claim 2 , wherein the at least one welding parameter includes at least one of a travel speed of the IR laser beam, a scanning frequency of the IR laser beam, a duration at which the IR laser beam heats the at least two plastic components, and a size of a laser focal diameter of the IR laser beam. 
     
     
         4 . The system as recited in  claim 1 , wherein the control module includes control logic for controlling a specific amount of energy per surface area created along the joining surfaces of the at least two plastic components. 
     
     
         5 . The system of  claim 1 , further comprising a second IR laser beam source. 
     
     
         6 . The system of  claim 5 , wherein the second IR laser beam source is positioned directly adjacent to the at least one IR laser beam source, and wherein the second IR laser beam generates a second IR laser beam for heating at least one of the joining surfaces of the at least two plastic components to the welding temperature. 
     
     
         7 . The system of  claim 5 , wherein the at least one IR laser beam source is positioned above a first joining surface of a first plastic component, and the second IR laser beam source is positioned below a second joining surface of a second plastic component. 
     
     
         8 . The system of  claim 1 , wherein the IR laser beam includes a wavelength of least about 2000 nm. 
     
     
         9 . The system of  claim 1 , wherein the at least one IR laser beam source is one of a diode laser, a solid-state laser, and a gas laser. 
     
     
         10 . A method of welding at least two plastic components together, wherein the at least two plastic components are welded together at respective joining surfaces, the method comprising:
 directing at least one infrared (IR) laser beam along the joining surfaces of the at least two plastic components, wherein the at least one IR laser beam heats the joining surfaces of the at least two plastic components to a welding temperature; and   clamping the at least two plastic components together at the joining surfaces to create a weld.   
     
     
         11 . The method as recited in  claim 10 , comprising adjusting at least one welding parameter of the at least one IR laser beam. 
     
     
         12 . The method as recited in  claim 11 , wherein the at least one welding parameter includes at least one of a travel speed of the at least one IR laser beam, a scanning frequency of the at least one IR laser beam, a duration at which the at least one IR laser beam heats the at least two plastic components, and a size of a laser focal diameter of the at least one IR laser beam. 
     
     
         13 . The method as recited in  claim 10 , comprising controlling a specific amount of energy per surface area created along the joining surfaces of the at least two plastic components. 
     
     
         14 . The method as recited in  claim 10 , comprising a second IR laser beam, wherein the at least one IR laser beam melts a first joining surface of a first plastic component and the second IR laser melts a second joining surface of a second plastic component. 
     
     
         15 . The method as recited in  claim 10 , comprising rotating both the at least two plastic components by about ninety degrees before clamping. 
     
     
         16 . The method as recited in  claim 10 , comprising translating at least one of the at least two plastic components in a linear direction before clamping such that a first joining surface of a first plastic component generally opposes a second joining surface of a second plastic component. 
     
     
         17 . The method as recited in  claim 10 , comprising applying a coating to the joining surfaces of the at least two plastic components. 
     
     
         18 . The method as recited in  claim 10 , comprising adding a colorant to a material the at least two plastic components are constructed of, and wherein the colorant absorbs energy emitted by the IR laser beam. 
     
     
         19 . The method as recited in  claim 10 , wherein the at least one IR laser beam includes a wavelength of least about 2000 nm. 
     
     
         20 . The method as recited in  claim 10 , wherein the wherein the at least one IR laser beam is 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.