Abstract: A low mass staking module includes a punch having a cavity on a first side, a contact surface on the second side opposite the first side, and a circular flange extending about an outer edge thereof, the punch formed of a thermally-conductive material, an annular housing engaged with the punch about the circular flange at a first end, and a heating element located inside the annular housing. The heating element has an output side in contact with the contact surface of the punch, the contact surface having a shape conforming to a shape of the output side of the heating element. The punch is desirably a low thermal mass punch, while the heating element may be a high power (watt) density, solid state, ceramic, resistant heating element (e.g., aluminum nitride or boron nitride heaters).

Abstract: An infrared welder for thermoplastic materials comprising the combination of a halogen lamp producing illumination in the infrared band located at the focal point of a first parabolic reflector. The parabolic reflector is joined in a substantially continuous fashion with a non-imaging lower reflector such as a Winston cone or a “CPC” having a lower aperture through which essentially all of the radiation from the source is directed. The aperture defines the shape and size of the weld area. The lower reflector may be brought into contact with the thermoplastic materials during the welding operation. Alternatively, a selectively operable press device may be used. Several embodiments are disclosed including embodiments which produce circular spot welds, linear welds, curved welds and corner welds.

Abstract: A machine for heat staking utilizes an infrared heat lamp to direct radiant energy onto a plastic stud to heat and soften the plastic material prior to the staking punch impacting the stud. In a first embodiment of the invention, the lamp is mounted directly above and in coaxial alignment with the staking punch such that the lamp points downward toward the plastic stud. An annular reflector is positioned in a radially surrounding relationship to the stud such that all of the radiant energy emitted by the lamp strikes the reflector and is redirected radially inward onto the stud. In an alternate embodiment of the invention, an infrared lamp is mounted on a non-moving portion of the staking press machinery and one or more fiber-optic cables extend from the lamp to the vicinity of the stud. The fiber-optic cables gather substantially all of the radiant energy produced by the lamp and direct it onto the stud.